Lesson Plan-Week 5 Topic: The 7 Types of Waste

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1 Lesson Plan- Topic: The 7 Types of Waste Warm-Up Exercise: Have a juggling contest. Everyone in the room that doesn t know how to juggle gets to try to distract those who are juggling. Give the winner a big standing ovation OR YOU COULD CREATE YOUR OWN WARM-UP EXERCISE! Success Factors: This lesson will be a success if we Understand the purpose of naming each kind of waste Understand each of the seven types of Waste Introduction Points: Start by explaining why we name each kind of waste. You may ask the group to see if anyone has a guess as to why we give waste a name. o We name the 7 different types of waste because if you can name it, then you understand it. If you understand it, it is much easier to both identify when it is happening and eliminate it from happening. o It is going to be very helpful for us in looking at our Process Maps again next week to be able to identify where the waste is happening. Key Points and Discussion: Pass out the 7 Types of Waste handout to everyone. Ask for a volunteer to read off each of the 7 types of waste as you give the following example of each type of waste. After you give an example, you might see if anyone can think of a different example. Have someone read the definition of Transport waste from the handout. o An example of transport waste would be if a pizza delivery driver wasn t quite sure where the address he was supposed to deliver to is located so he wasted 5 minutes driving around trying to find it. Have someone read the definition of Inventory waste. o An example of Inventory waste would be if the manager at the pizza store ordered twice as many special edition Star Wars pizza boxes as they needed just because he was a big Star Wars fan. Have someone read the definition of Motion waste.

2 Page 2 o An example of Motion waste would be if the pizza store manager kept the copy machine back by his office for his convenience even though the cashier used it 15 times a night and had to walk all the way to the back of the store to use it every time. The cashier walking to the back of the store is motion waste when the copy machine should be closest to the person who uses it most often. Have someone read the definition of Waiting waste. o An example of Waiting waste would be if at the pizza store the delivery guys played cards while they waited for deliveries to come in as opposed to cleaning the store, taking orders, or doing something that would provide value to the customer. Have someone read the definition of Overproduction waste. o An example of Overproduction waste would be if you staffed the pizza store with 3 people making pizzas when the work could easily be done by 2 people. Have someone read the definition of Over-processing waste. o The person who puts the prepared pizza into the oven is very particular about the way the pepperoni is arranged so always stops to rearrange it in a way he wants after someone else put on the pepperoni. If standard work were in place for this, then it would be put on the correct way the first time. Have someone read the definition of Defects waste. o An example of Defects waste would be to deliver a pizza to a customer that tastes like it just came out of the refrigerator instead of the oven. To please the customer, you make them a fresh pizza and deliver it promptly to assure it is hot. Not only does the defective pizza hurt your brand, it leads to additional waste occurring in making the extra pizza (Over-processing) and the extra delivery (Transport). It s helpful to find a way for everyone to commit the 7 Types of Waste to memory. You might want to introduce the mnemonic device: T.I.M. W.O.O.D. This obviously stands for each of the 7 Types of Waste. Brainstorm & Engage: Now it s time to have a little fun. Have everyone get into groups of 4-5. Try to form groups with people other than those you worked with on Process Mapping last week. Each group needs to create a 15-second public service announcement to warn of the danger the 7 Types of Waste pose to your business. This short commercial can be humorous, or you can make it very serious.

3 Page 3 Give each group 5 minutes to come up with a public service announcement, and then allow each group to present their commercial. After each group presents, give them a standing ovation, or possibly you might even start a Down with Waste chant after each group presents. Recap: Ask someone to remind us why we give Waste a name. o If we name it, we understand it. If we understand it, we can recognize and eliminate it. Quote of the Week and Builder/Destroyer Poster: The most dangerous kind of waste is the waste we do not recognize. -Shigeo Shingo o What do you think this means and how does it relate to today s lesson? Have someone read the Builder Tip and Destroyer Trap and post copies on your Working Smarter communication board and in different areas around the company. Next Week s Lesson: Identify Waste In Your Process Map If someone else will be facilitating next week, recognize that person. Explain the topic o The real purpose of drawing a Process Map is to identify waste in our processes. Next week we are going to put our Process Maps to use for us and use our knowledge of Waste from today to start to identify where we can improve our processes. THANK EVERYONE FOR THEIR TIME AND PARTICIPATION!

4 The 7 Types of Waste Page 4 1. Transport Definition: Unnecessary movement of materials, equipment or people 2. Inventory Definition: Too many materials delivered to a site; wasted materials or resources; overstock parts or supplies 3. Motion Definition: Unnecessary steps taken by employees or equipment because of poor planning, equipment, or communication 4. Waiting Definition: People standing because of lack of information, poor organization, unpreparedness of foreman, or site conditions 5. Overproduction Definition: Too many people on the job, providing more quality than needed, doing work that is not on the work order 6. Over-processing Definition: Reworking because of lack of information, materials, equipment, or not having standard work 7. Defects Definition: Machine breakdowns, poor quality of materials, and ultimately service calls and replacements

5 BUILDER DESTROYER TIP... TRAP... BUILDERS know how to stay ENERGIZED in learning and mastering new things. They realize that most great things take time and become very aware of little successes on the way to GREAT ACCOMPLISHMENTS. DESTROYERS are generally the first to bring up that something is not going to work or last. They spend most of their time seeking out reasons, whether real or imagined, why something will fail. As they are proclaiming that something cannot be done, they are usually passed by someone who is doing it.