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3 MU

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Why elimination of the "3 mu" is at the heart of kaizen?

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3 MU

  1. 1. Muda, Mura & MuriWhy elimination of the "3 mu" is at the heart of kaizen? Anand Subramaniam
  2. 2. “The greatest wastes are unused talents and untried ideas..” - Unknown Source 2
  3. 3. 3 MU Muri Muda Mura • Unevenness• Unreasonableness • Unusefulness • Shifts in demand• A process, system, • An activity within or delivery that or facility designed a process that lead to a service beyond the physical does not add or support capacities of value, from the process being employees / perspective of the sped up or slowed equipment customer down (unsteady) 3
  4. 4. Taiichi Ohno The Father of Toyota Production System, JIT, and Lean Manufacturing Identified the 7 types of Muda 4
  5. 5. What is Waste ?Waste is “anything other than the minimum amount of equipment, materials, parts, space, and worker’s time which are absolutely essential to add value to the product.” Shoichiro Toyoda President, Toyota 5
  6. 6. Why Look @ Waste Reduction 6
  7. 7. Waste - Root Causes WOMBAT = Waste of Money, Brains And TimeInflexibility Variability Redundancy Schedule Task 7
  8. 8. Waste Types Transport Motion ReworkOverproducing Inventory Waste Types Overprocessing Intellect 8
  9. 9. Waste Types (Contd.) Transport  Movement of product that does not add value Inventory  Ties up capital, takes valuable space, requires moving, difficulty in finding material, obsolescence, losses due to damage  Reduces customer responsiveness and multiplies quality problems 9
  10. 10. Waste Types (Contd.) Motion  Movement of people that does not add value Waiting  Idle time created when material, information, people, or equipment is not ready Under utilising talent  Under utilising employees’ potential (their creative ideas) 10
  11. 11. Waste Types (Contd.) Over processing  Effort that adds no value from the customer’s viewpoint Defect  Work that contains errors, rework, mistakes or lacks something necessary  Creating / correcting defects robs resources, “chokes” flow 11
  12. 12. Waste Types (Contd.) Overproduction  Producing more than the customer needs right now  Consumes valuable resources not immediately needed  Hides other process problems (bad quality, poor scheduling, poor delivery)  Builds inventory not needed 12
  13. 13. Waste Hierarchy By Reducing waste, we minimise the load on landfill and transport By sorting our wastes, we make it easier to Reuse and Recycle 13
  14. 14. Lean Tool to remove WasteInput Waste Lean ToolMan  Motion  Standard Work  Walking  5 S’s  Waiting  3P (Product Preparation  Searching Process)Machine  Motion  3P  Setup/Change over  Setup Reduction  Breakdown  TPMMaterial  Inventory  Pull SystemMethod  Batch production  Flow Production  Transportation  One Piece Flow 14
  15. 15. “It has been my observation that most people get ahead during the time that others waste.” - Henry Ford 15
  16. 16. Good Luck 16