|
13 May 2009
Identifying Waste
What is increasing repair costs without adding any value to your customers?
Muda (waste) can be designated as:
-
Type 1 Muda: tasks or steps that do not add any value to the vehicle owner, but are standard operating procedures required by the body shop and/or insurance company.
-
Type 2 Muda: tasks or steps that do not add any value to the vehicle owner, nor are they standard operating procedures required by the shop and/or insurance company.
The 8 Types of Muda (waste) to Look for During Your Waste Walk:
-
Waiting: Waiting of any kind is waste. If People, Equipment, Information, Parts or Materials delay production, time is wasted: increasing cycle times and production costs.
-
Overproduction (extra work): Producing more than the customer requires. Eg. When significantly more extra work is required to repair a part rather than replace it. The customer can be the vehicle owner or an internal customer (another department).
-
Defects (Redos): caused by human error or equipment malfunction; Redos are a preventable waste of labour time and material.
-
Processes: Extra steps in the repair process taken by body shop personnel. This can include anything from dual computer entry of customer data to over sanding a panel.
-
Inventory: Excess inventory can tie up cash; occupy needed production space in the shop; and be at risk of being damaged or becoming obsolete. Work in Process is also a form of inventory.
-
Transportation: the excess movement of things: vehicles, parts, materials, equipment, or information from one area of the shop to another.
-
Motion: the unnecessary movement of people: you and your staff walking around the shop looking for information, parts, materials and equipment needed for the repair, that should be in a clearly identified location near the work station.
-
Employee Potential: the loss of time, skills, ideas, opportunities, and talent that results when the people actually doing the work are not listened to.
The definitions listed above are based on the following sources:
www.manufactus.com
www.LEAN2020.com
“Lean for Dummies” by Natalie J. Sayer and Bruce Williams
“Lean Thinking” by James P. Womack and Daniel T. Jones, DuPont Performance Coatings
| |
