{"id":1301,"date":"2013-09-24T09:00:05","date_gmt":"2013-09-24T14:00:05","guid":{"rendered":"https:\/\/www.insta-pro.com\/?p=1301"},"modified":"2025-12-18T10:23:06","modified_gmt":"2025-12-18T16:23:06","slug":"tom-d-wip-lean-manufacturings-enemy","status":"publish","type":"post","link":"https:\/\/instapro.spinuhost.com\/en\/blog\/businessstrategyandfinance\/tom-d-wip-lean-manufacturings-enemy\/","title":{"rendered":"TOM D WIP \u2013 Lean Manufacturing\u2019s Enemy"},"content":{"rendered":"<p>Lean manufacturing is a concept that has been around for a while and has become the go-to buzzword over the last several years.\u00a0 Every company wants to create a \u201clean\u201d culture that promotes efficiency, productivity and minimal errors.\u00a0 How do you go about this in your own plant?<\/p>\n<p>At the cornerstone of most lean cultures is the <a href=\"http:\/\/en.wikipedia.org\/wiki\/Toyota_Production_System\">Toyota Production System<\/a> (or \u201cTPS\u201d).\u00a0 This methodology has been used in countless manufacturing settings and can be applied virtually anywhere.\u00a0 A key concept with this is waste reduction, which is referred to as \u201cMuda\u201d in the TPS.\u00a0 Every process can be classified as either \u201cvalue-add\u201d or \u201cnon value-add\u201d and deciding what processes fall into each category will help your facility become more efficient.\u00a0 While it is true that eliminating wastes will create a more efficient process, where does one start?\u00a0 A simple way to think and evaluate each process goes as follows.<\/p>\n<p>&nbsp;<\/p>\n<p><b><span style=\"text-decoration: underline;\">The 7 Types of Waste<\/span><\/b><\/p>\n<p>There are several common phrases for this, but taking the first letter of each waste gives the following pneumonic: TOM D WIP.\u00a0 By evaluating each process, one can identify sources of inefficiency and correct them.\u00a0 Every process should be evaluated for value-added and non value-added benefits.<\/p>\n<p><b>T \u2013 Transportation<br \/>\n<\/b>How many times is product moved during the process?\u00a0 Every time something is transported, the risk of it becoming damaged, lost or worse, increases.\u00a0 The less the product is moved, the better.\u00a0 An example of this is post bagging.\u00a0 Ideally after bagging, product could go directly to shipping.\u00a0 Any storage stops present an opportunity for product to be damaged.<\/p>\n<p><b>O \u2013 Overproduction<br \/>\n<\/b>Overproduction has a tendency to hide problems.\u00a0 Large batches are usually run in order to make up for lost time with excess amounts being made to account for production issues.\u00a0 If a recall occurs, the batch size is now potentially larger than it could have been, resulting in more discarded product.\u00a0 Another problem occurs if there is a momentary issue in production (mis-fed material, surging, etc.).\u00a0 This could go undetected due to the large amount of product until it reaches the customer.<\/p>\n<p>Overproduction reduces the amount of control one has over the process and usually leads to another form of waste: excessive inventory.\u00a0 It can snowball from there: you now have to find room to put everything which can lead to delays and potential defects because items are getting in the way.<\/p>\n<p><b>M \u2013 Motion (excess)<br \/>\n<\/b>How far away does product need to travel to be processed next?\u00a0 If the next process is a long distance away, extra time is required before product can be processed.\u00a0 Very long conveyor lengths or excessive distances between machines are likely causes.\u00a0 This can applied to operators, too. \u00a0As an example, if an operator needs to monitor production speed and also operate a bagger, there could be excessive walking involved.\u00a0 Perhaps redistributing workloads or even hiring extra help will increase efficiency and reduce wait times for this process.<\/p>\n<p><b>D \u2013 Defects<br \/>\n<\/b>Any defective product is obviously a waste.\u00a0 A reduction of defects is an automatic boost in efficiency.\u00a0 Defects either require rework or discarding, both of which cost extra time and money.\u00a0 There are some process-specific things that could be causing defects such as over-heating or poor handling of pellets, but these are likely caused as\u00a0a result of the wastes shown here.\u00a0 If the actual production seems correct but issues still exist, defects may be a by-product of other wastes.<\/p>\n<p><b>W \u2013 Waiting<br \/>\n<\/b>As the adage goes, \u201ctime is money\u201d.\u00a0 The longer things take to produce, the more money is spent on them due to operational costs.\u00a0 Waiting occurs when there is not a steady production flow.\u00a0 Any product waiting to be processed is taking up space.\u00a0 This is usually present in batch-type systems.\u00a0 A reduction in waiting allows the process to run smoother since it reduces production surging.<\/p>\n<p>I<b>\u00a0\u2013 Inventory<br \/>\n<\/b>What happens when you have too much product?\u00a0 Storing excessive amounts of product is usually unnecessary.\u00a0 This takes up space and can make moving within the plant difficult.\u00a0 Work-space is a premium these days and the more efficiently it can be used, the better.\u00a0 Inventory needs to be evaluated and assessed to make sure the items being stored make sense.\u00a0 Do you have a stockpile of parts that only get used once in a great while?\u00a0 Perhaps these can be moved in favor of more processing space or is needed for higher-turnover items which can help response time to customers.<\/p>\n<p><b>P \u2013 Processing (excess)<br \/>\n<\/b>Over processing involves adding more to the product\/process than necessary.\u00a0 Why dry a product to 5% moisture when 8% will do?\u00a0 Is it necessary to have 13 vitamins when the customer only asked for 11?\u00a0 When evaluating over processing, one has to weigh the cost to the benefits.\u00a0 If drying or processing below a certain point is extra assurance or a marketing strategy, the cost of this needs to be considered against the operational costs in order to justify it.\u00a0 If these are done to compensate for other production issues, fixing other forms of wastes is a likely (and better) use of resources.<\/p>\n<p><a href=\"https:\/\/www.insta-pro.com-content\/uploads\/2013\/09\/2.jpg\"><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-medium wp-image-1303\" src=\"https:\/\/www.insta-pro.com-content\/uploads\/2013\/09\/2-225x300.jpg\" alt=\"2\" width=\"225\" height=\"300\" \/><\/a><\/p>\n<p><b><span style=\"text-decoration: underline;\">What can I do?<\/span><\/b><\/p>\n<p>No process is perfect, but the fundamental idea of continuous improvement should always be present.\u00a0 There are always ways to improve and become more efficient.\u00a0 A great place to start is to write out every process step in detail, including cycle time on a note card, one process step per card.\u00a0 Depending on how large your facility is, this could take several note cards!\u00a0 Using cards is a visual way to understand if there are wastes in the system.\u00a0 You can then reorganize processing steps or evaluate them to see if they are necessary or not.\u00a0 In the end, you may find you can gain efficiency for free.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Lean manufacturing is a concept that has been around for a while and has become the go-to buzzword over the last several years.\u00a0 Every company wants to create a \u201clean\u201d culture that promotes efficiency, productivity and minimal errors.\u00a0 How do you go about this in your own plant? At the cornerstone of most lean cultures [&hellip;]<\/p>\n","protected":false},"author":68,"featured_media":10858,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[31,7176],"tags":[92,36,93,69],"class_list":["post-1301","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-businessstrategyandfinance","category-engineeringandmaintenance","tag-business-strategy","tag-creating-a-profitable-plant","tag-processing-feed-or-food","tag-profitable-feed-processing-plant"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v26.2 (Yoast SEO v27.3) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>TOM D WIP \u2013 Lean Manufacturing\u2019s Enemy | Insta-Pro Intl<\/title>\n<meta name=\"description\" content=\"The 7 Types of Waste are abbreviated as TOM D WIP. 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