Unit 4


Eliminate MUDA and
Assess effectiveness of
the solution

03/06/2025 1
 Learning
Objectives

At the end of this chapter the students will be able
to:
 Prepare and implement elimination plan of MUDA
 Aware necessary attitude to eliminate MUDA
 Describe the ten basic principles to eliminate
MUDA
 Discuss tools and techniques to eliminate
wastes/Muda.
 Reduce and eliminate Wastes/MUDA.
 Report Improvements
03/06/2025 2
 Preparing and Implementing
Plan of MUDA Elimination

Planning for Elimination of the 7 Types of
Wastes
 A plan prepared to eliminate MUDA/waste
should identify
 what the muda is,
 what is its cause,
 how it is fixed (methods used to fix or eliminate
the MUDA) and
 when to fix the problem (the time plan).

03/06/2025 3
 Cont.…

 The following sample action plan may be used
as an action plan to eliminate any of the seven
MUDA in the work place.

03/06/2025 4
 4.2 Adopting the
Necessary Attitude to
eliminate
 MUDA
 First you must adopt an attitude that supports
your ability to see waste.
 Waste is hard enough to find when you want
to find it;
 if you don‘t want to find it, or
 if your response to find it is denial or resistance,
 then it will never be possible for you to root out
waste and make your work environment stress
free.

03/06/2025 5
 Cont.…

 It is very important that you understand that
one purpose of discovering waste is to take
the frustration out of your work.
 Many people will resist seeing the waste in
their work.
 Just don‘t let it be you.
 You may hear yourself or others saying things
like:
 Let‘s not fix what is not broken.
 Can‘t we live well enough alone?
03/06/2025 6
 Cont.…

 This is just another attempt to make us work
harder for the same amount of money.
 It looks good on paper, but it will never work on
the floor.
 We tried that twenty years ago.
 It didn‘t work then; it won‘t work now.
 That is not my job. and so on.
 Resistance is normal.
 Just don‘t let it keep you from learning to see
the waste in your work.
03/06/2025 7
 Cont.…

 In the end, you are the one who suffers most
from the results of waste.

03/06/2025 8
 4.3 The ten basic
principles to eliminate
MUDA

 Throw out all of your fixed ideas about how to do
things.
 Think of how the new method will work-not how it
will not.
 Don’t accept excuses. Totally deny the status quo.
 Don’t seek perfection. A 50 percent
implementation rate is fine as long as it is done
on the spot.
 Correct mistakes the moment they are found.
 Don’t spend a lot of money on improvements.
03/06/2025 9
 Cont.…

 Problems give you a chance to use your brain.
 Ask “Why?” at least five times until you find
the ultimate cause.
 Ten people’s ideas are better than one
person’.
 Improvement knows no limit.

03/06/2025 10
 Methods of Eliminating
Wastes/Muda.

Waste of overproduction (largest waste)
 Just-in-time production systems create
products at the rate they are needed
 Pull systems in production can be used to
tailor production to meet demand
 More accurate sales projections can reduce
overly-high targets and rebalance production
priorities

03/06/2025 11
 Cont.…

Waste of time on hand (waiting)
 Process mapping and BPMN techniques allow
managers to see an overview of entire flows
 Increased communication with suppliers or
deliveries to combat downtime
 Flexible labor force capable of taking on
responsibilities across different company areas

03/06/2025 12
 Cont.…

Waste of transportation
 Moving aspects of production to be localized,
possibly as part of increased vertical
integration
 Mapping transport flows in the production
process and seeking to streamline and
standardize these patterns
 Increased digitization or paperwork reduction
to decrease movement in business processes.

03/06/2025 13
 Cont.…

Waste of processing itself
 Value stream analysis, also known as
information-flow mapping
 Waterfall diagrams help companies measure
the cumulative effect of sequential variables
 Streamlining standard operating procedures to
reduce overall volume of documentation

03/06/2025 14
 Cont.…

Waste of stock at hand
 Tackle waste of overproduction if it is seen to
be the underlying cause
 Reassess production targets in order to better
meet demand
 Analyze the production rates of slow-moving
stock with variable demand

03/06/2025 15
 Cont.…

Waste of movement
 motion is not the same as transportation
waste.
 Assembly lines can minimize worker
movements
 Clear categorization and availability of needed
tools or equipment
 Effective training procedures and easily
accessible and actionable standard operating
procedures
03/06/2025 16
 Cont.…

Waste of making defective products
 Avoid segmenting quality control
departmentally;
 quality control can benefit from a holistic
perspective
 Use techniques like the DMAIC process and
other Six Sigma methodologies to tackle
defects
 Make sure workers are appropriately trained
and standardized processes are being
adequately followed
03/06/2025 17
 4.4 Tools and techniques
to eliminate wastes/MUDA

5S (Five S)
 It involves implementing 5S/workplace
organization to eliminate Wastes/Muda.
 Problems cannot be clearly seen when the
work place is disorganized.
 Cleaning and organizing the workplace helps
the team to uncover problems.
 Making problems visible is the first step of
improvement.

03/06/2025 18
 Cont.…

Layout Improvement
 Is to plan the placement of machineries, raw
materials, workers, etc. in order to produce
raw materials, parts or products economically.
 When the layout of a shop floor is decided, it
is necessary to plan considering production
conditions and environmental conditions
appropriately.
 Layout improvement is important technique to
avoid Muda, Mura and Muri due to placement
in production activities.
03/06/2025 19
 Cont.…

Brainstorming
 Brainstorming can be used to list down all the
problems faced by an organization, their causes
and the potential effects if a certain suggestion
is implemented.
 Rules of brainstorming process are:
 The subject for brainstorming should be clear and
accurate.
 Each member will give only one opinion / idea at
each turn regardless of the number of ideas he /
she may have.
03/06/2025 20
 Cont.…

 A tension-free atmosphere must be maintained
to encourage free expression of ideas.
 Every idea expressed should be written on the
black / white board, flip chart or noted down by
a secretary.
 At the end of the brainstorming session, all the
ideas expressed should be evaluated one by
one and short-listed.

03/06/2025 21
 Cont.…

And on
 Is an indicator informing team leaders and
supervisors of the current workshop situation
with color boards, flash lights, and automated
announcement.
U-line
 Is a layout in which the inlet and outlet are
positioned in the same direction to avoid
walking back for a single operator

03/06/2025 22
 Cont.…

Multi-process handling and Multi-skilled
operators
 Multi-process handling- means that a single
operator manages multiple machines and
processes in product processing and
assembling.
 This is the primary factor for constructing lines
by a small number of operators.
 A multi-skilled Operator- can deal with several
machines or processes as described above.
03/06/2025 23
 Cont.…

 The supervisor can make a flexible placement
of operators when someone within the same
team or section is absent.
 control (Two point control): Is a devised
automatic control function.
 It controls the machine movement when they
come to start or stop working depending upon
the number of work pieces piled up between
the preceding process and the following
process.
03/06/2025 24
 Cont.…

Line balancing:
 Refers to the state where there is a difference in time
required for each process of a production line.
 It is determined that the line balance is good if this
difference is small (usually smaller than 15%), but in
a bad case the line balance should be improved by
leveling out the work time through
 shortening that of a very time-consuming process and
 increasing loads of processes consuming less time.

03/06/2025 25
 Cont.…

Build in quality at each process
1. Quality should be built into each process.
2. Guarantee the quality in each process.
 Do not make Defect
 Do not pass defect
 Work to standard

03/06/2025 26
 Cont.…

 If machines stop abnormally during operation:
 Worker stops operation, if he/she finds
abnormality.
 Don‘t send the next process the defects.
 Abnormality will understood simply.
 Visual control
 visually control the states,
 ANDON,
 Production analysis board,
 Standardized work chart etc.
03/06/2025 27
 Cont.…

Kanban System
 It‘s a TOYOTA Production System
manufacturing tool.
 Kanban is not inventory control system rather
it is scheduling system.
 In production it tells us:
 What to produce
 When to produce it
 How much to produce

03/06/2025 28
 Cont.…

Total Productive Maintenance (TPM)
 Total means all individuals in the organization
working together.
 Productive means Production of goods that
meet or exceed customer‘s expectations.
 Maintenance means keeping equipment and
plant in good condition at all times.

03/06/2025 29
 Cont.…

 Total Productive Maintenance (TPM) is a
maintenance program which involves a newly
defined concept for maintaining plants and
equipment.
 The goal of the TPM program is
 to markedly increase production
 while, at the same time, increasing employee
morale and job satisfaction.

03/06/2025 30
 Cont.…

 TPM was introduced to achieve the following
objectives.
 The important ones are listed below.
 Avoid wastage in a quickly changing economic
environment.
 Producing goods without reducing product quality.
 Reduce cost.
 Produce a low batch quantity at the earliest possible
time.
 Goods send to the customers must be non-
defective.
03/06/2025 31
 4.5 Reducing and eliminating
Wastes/MUDA

Eliminating waste
 You should always start with identifying the
value according to the customer.
 Make that value adding processes flow through
your organization at the pull of the customer.
 "When you go out into the workplace, you
should be looking for things that you can do for
your people there.
 You've got no business in the workplace if
you're just there to be there.
03/06/2025 32
 Cont.…

 You've got to be looking for changes you can
make for the benefit of the people who are
working there.
 Before one can stop waste,
 he/she should able to see it,
 recognize it as waste,
 identify who is responsible, and
 finally appreciate its size and magnitude.

03/06/2025 33
 Cont.…

 Waste that is not seen cannot be eliminated.
 When something is denied as waste, it also
cannot be stopped.
 When one refuses to accept responsibility for
the waste, then he will not eliminate it.
 Finally, when the waste is not measured,
people may think it is small or trivial and
therefore will not be motivated to stop it.
 As the saying goes
 What is not measured, is not improved.
03/06/2025 34
 Strategies used for reducing the seven
types of Muda

03/06/2025 35
 4.6 Reporting
Improvements

 Reporting means relating to the issuing of reports.
 A reporting entity is an organization or company,
or group of companies that prepares financial
reports.
 Reports communicate information which has been
compiled as a result of research and analysis of
data and of issues.
 Reports can cover a wide range of topics, but
usually focus on transmitting information with a
clear purpose, to a specific audience.

03/06/2025 36
 Cont.…

Types of report
 There are different types of reports.
 Among those the following are listed below.
 Formal or Informal Reports
 Short or Long Reports
 Informational or Analytical Reports
 Proposal Report
 Vertical or Lateral Reports
 Internal or External Reports
 Periodic Reports
03/06/2025 37
 Cont.…

 Structure material in a logical and coherent
order;
 present your report in a consistent manner
according to the instructions of the report
brief;
 make appropriate conclusions that are
supported by the evidence and analysis of the
report;
 make thoughtful and practical
recommendations where required.
03/06/2025 38
 Cont.…

Characteristics of Good or Essential report
 Suitable Title
 Simple
 Comparability
 Consistency.
 Precise and Accurate
 Relevant Information
 Presented to Required Person or Group or
Department
03/06/2025 39
 

Thank you

03/06/2025 40