2/20/2025

Contents
SNPRS TEVT
 The concept of MUDA/Waste
 Methods for categorizing types of Muda
 MUDA identification
GAZER CONSRACTION
AND INDUSTRIAL COLLEGE  Elimination of Muda
DEPARTMENT OF MANUFACTURING  Methods for Muda prevention

Fbruaryuary, 2024
Gzer,Ethiopia
3

Concept of MUDA

CROP PRODUCTION
LEVEL- II

ELIMINATE & PREVENT MUDA

By: Melese .A

1
 2/20/2025

What is Waste/MUDA?
Non-value adding and wastes Value adding
Muda is a Japanese word meaning Wasteful Activity • movements • Seeding
• It is anything unnecessary in operation. • searching for tools • Diging
• It is also defined as any activity which consumes • transporting materials • spraying
resources without adding value. • over production • mixing
• Resource = money, time, energy, materials, etc • waiting /idle time • building
• making defects etc • milling etc

5 7

Why Eliminate muda? ሦስቱ ‘ሙ’ ዎች/The three MU’s/

• It must be eliminated immediately

ክፍል 2
because:
• It increases Production cost
• Affects the quality of the product የብክነት መንስሔዎች
• Delay delivery time

federal Tvet agency and EKI 6

2
 2/20/2025

ሦስቱ ‘ማ’ዎች Counted…

MUDA-Capacity exceeds load.
MURA (imbalance or variation) = capacity sometimes
muda
mura exceeds the load and the load sometimes exceeds capacity.
የሸከም
ብክነት MURI(Physical or mental overburden)- Load exceeds
አለመመጣጠን
capacity .
Productivity improvement does not mean hard
work.

muri
የስራ ጫና
freeleansite.com 11

Counted… Contend…
 Muri
MUDA-Capacity exceeds load.
• Mental and physical overburden on operators, and
overburden on production machinery

• Load exceeds capacity

10 12

3
 2/20/2025

Muri : overburden

13 federal Tvet agency and EKI 15

Counted…
Counted…
 MURA
 (imbalance or variation) = capacity sometimes
exceeds the load and the load sometimes exceeds
capacity.

Variation in work distribution, production capacity

of machinery, and material specifications

16

4
 2/20/2025

Counted…

IN OUT

17 federal Tvet agency and EKI 19

Counted…
Relationship between the 3 MU’s

Usually Mura creates Muri which in turn

lead to generation of Muda

federal Tvet agency and EKI 18 20

5
 2/20/2025

Conted… Waste/muda prevention

 way of thinking in the areas where waste may occurs 5M(man,
Therefore, mura creates muri that material, machine, method and management), plus Quality and
undercuts previous efforts to eliminate Safety. (5M+Q+S)

muda.  Material:
Waste of:- Parts, Bolts, Welds, Functions, Storage & Handling.
 Man/Workers
Eliminating mura is fundamental to the Waste of:- Walking, Waiting, Searching, Unnecessary movements
complete elimination of muri and  Management
muda Waste of:- Materials, Meetings, Management control,
Communications, Vouchers
21 23

Contend… Conted…
 Machine
Waste of:- Large machines, General purpose machines, Conveyors, Machines
with wasteful movements, Breakdowns,
Machine handling.
 Method
Waste of:- Large lot production, Inventory, Conveyance, Retention, Non
standardization, Picking up setting down work pieces.
 Quality
Waste in:- Making defective goods, Fixing defects, errors, Inspection, Quality
control.
 Safety
Waste of:- Disaster prevention methods, Fixing defects.
federal Tvet agency and EKI 22 24

6
 2/20/2025

1)“Muda” of Overproduction
4)The Seven deadly wastes
1) “Muda” of Overproduction To produce things more than necessary in terms of
2) “Muda” of Inventory type, time, and volume. It is called “the worst kind
3) “Muda” of Waiting of Muda” since it hides all the other wastes.
4) “Muda” in Transporting Cost Reduction by Elimination of
muda
5) “Muda” of Defect-making
6) “Muda” of Motion
7) “Muda” in Processing

federal Tvet agency and EKI 25 27

1)“Muda” of Over production

[Effect ]
[Cause]
 Increase in inventory
Over Produced Excessive work force
Motion  Outbreak of defects
and facilities
7 Categories  Deterioration of turn-over
Transportation
of Waste Big and fast ratio of funds
Inventory
production machine  Advanced preparation of
Waiting
Lack of customer materials and parts
focus  Consumes resources
Defect Making
Over Processed  Needless wear on machines
federal Tvet agency and EKI 26 28

7
 2/20/2025

2) “Muda” of Inventory Examples of Inventory Wastes

The situation where items such as raw materials,
parts, and finished goods are stagnant or which
are not having value added to them. Some are
located in the warehouses, and others are in-
process inventory.

federal Tvet agency and EKI 29 federal Tvet agency and EKI 31

3) “Muda” of Waiting
2) “Muda” of Inventory  This includes all kinds of waste of time such as
[Cause]
[Effect ]
 Weak consciousness for inventory workers or parts waiting: -for an upstream process
 Waste of space
 Bottle-neck processing stage
 Needs for inspection, and to deliver,
 Advanced Production
 Approximate production transportation  for a machine to finish processing,
 Unreliable suppliers  Expansion of working fund
 Shelf life may expire
 for incoming parts or materials,
 It ties up cash  for process that has a long wait time
 Makes FIFO inventory
management more difficult

30 32

8
 2/20/2025

4) “Muda” in Transporting
It is Unnecessary movement of parts between
processes caused by unnecessary
transportation distance, temporary storage,
relocations or re-piling up.

33 federal Tvet agency and EKI 35

3) “Muda” of Waiting 4) “Muda” in Transporting

[Cause] [Effect ]
[Cause] [Effect ]
 Bottle-neck
processing stage Waste of
 Waste of space
 Bad facility layout manpower, time, &  Bad facility layout
 Production deterioration
 Capacity imbalance machines  Expansion of
 Shortages & Increase in the in- transportation
unreliable supply process inventory facilities
chain Failed delivery  Occurrence of scratches
 Lack of multi-skilling
 Poor maintenance.
dates  Increase production time
 wastes time and energy
Poor workflow
continuity
34 36

9
 2/20/2025

5) “Muda” of Defect-Making 6) “Muda” of Motion

This includes defects, inspections

for defects in-
process, and claims, rescheduling, and resource These are non-value adding movements or
loss. more than necessary movements of
workers, equipment, and machines, such
as looking for goods, bending, stretching,
walking, lifting, and reaching etc.

37 federal Tvet agency and EKI 39

5)“Muda” of Defect-Making
[Cause] [Effect ]

 Emphasizing on down-  Increase in material

stream processes by cost
inspection  Productivity
 Poor in methods and deterioration
standards for inspection  Increase in personnel &
 Lack of standard processes for inspection
operation  Increase in defects
and claims
 Invite reworking costs

federal Tvet agency and EKI 38 40

10
 2/20/2025

6)“Muda” of Motion 7)“Muda” in Processing

[Cause] [Effect ] [Cause] [Effect ]
 No education or  Increase in Lack of analysis of the  Unnecessary processes
training manpower and contents of operation or operation
 No standard processing  Improper tools and their  Increase in manpower
operating  Unstable use and man-hour
procedure operation
 Insufficient  Lower workability
 Isolated operation  Increases
standardization  Increase in defects
 Bad facility lay out production time
 Can cause injury Attitude - ‘Always do it  Can reduce life of
like this’. components
41 43

7) “Muda” in Processing Benefits of identifying & Eliminating waste

This consists of processing and operations 1. To the company

primarily unnecessary. It is processing  Cutting the hidden costs of production.
beyond the standard required by the  Increased customer satisfaction.
customer. 2. To Shop floor worker
 Increased job satisfaction
 Contributing for improvement

federal Tvet agency and EKI 42 44

11
 2/20/2025

Any questions…….?

federal Tvet agency and EKI 45

12