Question

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Q. How many mudas are defined under lean production? Explain.

Answer 1

Lean production, a management philosophy originating mainly from the Toyota Production Process, emphasizes on removing waste inside a industrial system, or "Muda."

Seven muda's or wastes are identified under lean production:

1. Overproduction
Overproduction, the foremost severe of the waste, will affect the opposite sorts of waste and cause a surplus inventory. an excessive amount of stock of an unfinished commodity has evident costs: transportation, lost resources, and unnecessary money locked up in worthless inventories.
Of course, the overproduction may have very severe environmental consequences counting on the commodity in question. More raw materials are consumed than necessary; the merchandise may spoil or become obsolete, which needs it to be thrown away; and, where the merchandise involves hazardous materials, more hazardous materials are wasted than necessary, leading to extra emissions, extra waste disposal costs, possible exposure of workers, and possible environmental problems that result from the waste itself.

2. Inventory
Inventory waste refers to waste generated through unprocessed inventories. That covers the value of production, the waste of cash locked up in unprocessed products, the waste of shipping merchandise, the containers wont to store inventory, warehouse room lighting etc. additionally , having an excess inventory may hide the first waste produced by the said inventory. Packaging, deterioration or damage to work-in - process, additional materials to exchange damaged or obsolete inventory, and energy to light — also as either heat or cool — inventory space are the environmental impacts of stock waste.

3. Motion
Wasteful motion is all of the motion that would be minimized, whether by an individual or a machine. When excess motion is employed to feature benefit that would are gained with but lost the quantity of motion. Motion could ask anything from a worker bending over to learning something on the factory floor to additional machine wear and tear, leading to capital depreciation to exchange .
Excess motion involves other environmental costs. One clear one is that the unnecessary waste of kit wont to repair broken machines; another would be the security facilities for overwhelmed workers, who wouldn't have needed them if activity had been minimised.

4. Defaults
Defects ask a product that deviates from the standard requirements, or from the requirements of the buyer . it's expensive to repair faulty products; they have paperwork and human time to try to to them; they'll eventually risk customers; the cash invested into the defective goods are lost if the products isn't purchased. In fact, a faulty component causes damage at certain stages that would have caused the defect; having a more productive manufacturing environment eliminates errors and improves the time required to repair them first.
The environmental costs of the defects include the raw materials used, the faulty parts of the merchandise requiring removal or recycling (which waste certain resources involved in repurposing it), and therefore the additional space needed and increased use of energy involved in handling the defects.

5. Over-processing
Over-processing refers to any excessive portion of the fabrication process. sorts of over-processing include painting an environment which will never be used, or incorporating elements which will not be seen. Essentially it refers to adding more value than required by the customer.
The impact on the environment involves excess parts, labour, and raw materials consumed in production. When wont to produce something that's unnecessary during a product, time, energy, and emissions are wasted; simplification and efficiency reduce these wastes and benefit the corporate and therefore the environment.

6. Waiting
Waiting refers to lost time in one phase of the availability process thanks to delayed or stopped production until a previous stage is finished. Just consider the classic example, if one job within the chain takes longer than another, the assembly line is wasted then the time the worker who is liable for subsequent job spends waiting. The more time-consuming job must be made simpler , more workers need to be added to assist , or the method has got to be more organized or designed to form up for this lost time.
During the waiting time, the environmental damage comes from unnecessary labour and electricity from lighting, heating, or cooling. Therefore, content would be contaminated, and parts could also be destroyed thanks to inadequate workflow.

7. Transportation
Transport transfers the products from one place to subsequent . The transport itself doesn't add much value to the commodity so it's important to scale back these costs. this suggests having one plant within the production chain closer to a different , or minimizing transport costs using more efficient methods. Resources and time are utilized in material handling, employing personnel to work transportation, training, safety precautions are implemented and additional space is employed . Transportation also will create waiting loss, together a part of the availability chain may need to await products to arrive.
Environmental risks to attend include carbon pollution, discarded shipping containers, possible disruption to the en-route commodity, also as an entire host of other waste that has the shipping of hazardous materials.