TYPES OF PRODUCTION WASTE EXAMPLES CAUSES Over-processing Work that could be. Poor product design Effort expended combined with other. Poor process planning/manufacturing engineeri which does not operations via fewer add customer individual parts or multiple operations on same equipmen Work performed on. Improperly sized equipment; poor maintenance; poor instruc wro ong-sized equipment, and training running time, or excess perating costs Enhancements Lack of clear customer requirements; tendency for engineers to precision beyond over-desigr customer needs aproper material Rework Excessive testing Poor product/process design; lack of qualified performance certification system Enterprise Level Waste 10/20/2002TYPES OF PRODUCTION WASTE EXAMPLES CAUSES Over-processing Effort expended which does not add customer value Work that could be combined with other operations via fewer individual parts or multiple operations on same equipment • Poor product design • Poor process planning/manufacturing engineering Work performed on wrong-sized equipment, requiring excess running time, or excess operating costs • Improperly sized equipment; poor maintenance; poor instructions and training Enhancements, precision beyond customer needs • Lack of clear customer requirements; tendency for engineers to over-design Improper material • Lack of current knowledge of alternative material capabilities Rework • Inadequate preventive maintenance; lack of automated process controls; poor workmanship Excessive testing • Poor product/process design; lack of qualified performance certification system Enterprise Level Waste 10/20/2002 9