The Seven Deadly Wastes

Transcription

1 The Seven Deadly Wastes Workbook The Learn what the waste of defect is, what causes it, and what lean tools are best suited to battle it. A workbook intended to accompany the Facilitator s Guides for this course. This guide includes the Key Points from the video, discussion items, quiz questions, and helpful tips. Using Gemba Academy s online learning content, any participant can use this workbook to facilitate learning in all courses. June 2017

2 Review What are Defects? Formally defined, defects are any work that is than the level the customer requested. These defects plague our companies in various ways. What do Defects Cost Us? Defects can be measured tangibly by looking at a company s costs, lost, costs, field service repairs, and lost. Our ability to spot defects early on can dramatically impact their cost to our companies: it s estimated that as defects pass through a process, the cost of fixing them multiplies by for each step they go through. Even if you can t eliminate the cause of the defect, the next best thing is setting up a system for defects and them from the production line. In our School of Six Sigma, we explore whether 99% good is good enough: the short answer is. Potential Causes of Defects A lack of checks can allow errors to move down the line and become more costly to correct. Low-quality from suppliers can force companies to spend millions of dollars repairing products before they can even think of adding value their customer is willing to pay for. Inadequate and poor or no can make workers confused and more likely to produce defects. 1

3 Tools to Combat Defects According to the principle, all associates are empowered and encouraged to stop the production line when a defect is detected in order to understand and address the root cause of the problem. Some companies experienced with lean principles use andon cords, which stop the whole production line when pulled. Pokayoke, or, makes it virtually impossible or at least very difficult to cause a problem or produce a defect. A common example of pokayoke in our daily lives is a printer: most printers make it difficult if not impossible to insert color cartridges the wrong way. Many sinks and bathtubs also come equipped with overflow holes in case the water is left running. analyses can help get to the root cause of a defect through constantly asking why until we find out why the defect occurred. diagrams (which we ll cover in more detail in our Six Sigma course) can help visualize what might be causing the problem. The head of the fish is the defect, and the potential causes form the bones. Jidoka, also called autonomation or automation with a, involves building machines so that they can sense when a problem occurs, stop what they re doing, and alert the operator to the problem. Often, all that s needed to get started with Jidoka are some inexpensive wired to a machine s controllers. As we hinted at earlier, the use of is another powerful approach many companies have leveraged to combat defects. Making sure employees have clear and standard work can also help eliminate defects. 2

4 Quiz 1. A defect is any work that is more than the level the customer has requested. True False 2. Is 99% good (only 1% bad) an acceptable performance level for critical processes? Yes No 3. Our ability to detect defects early in the process is important. True False 4. Which are potential causes of defects? Select all that apply. Low quality materials Incapable equipment Inadequate training Lack of in-process checks 5. Pokayoke is often referred to as this: Mistake Prone Defect Free Mistake Proofing Mistake Free 3

5 Reflection What has your experience with defects been? Have they affected you in your workplace? What about your daily life? 4