Lean manufacturing strategies require that we try to eliminate waste in all that we do. At Windsor Windows and Doors, we are committed to eliminating waste in our processes resulting in a greater value for our customers. These wastes have been defined more specifically and are sometimes known as the "Seven Wastes in Manufacturing" but can apply to other areas in your business. Each of the wastes is described in more detail below.
Overproduction- Producing items before the next customer is ready for them. Many times overproduction exists where excess inventory is seen.
Waiting- Waiting can occur when a production team member is idle during a machine cycle or upstream operations are not complete. Waiting can be used to determine the bottleneck step of a process.
Unnecessary transportation- Movement of work-in-process adds no value to the product and creates unnecessary transportation. Inlining or linking of processes can sometimes create large reductions in transportation.
Over processing or incorrect processing- This waste occurs when unneeded steps are taken in the process.
Excess inventory- Extra materials in the system cause longer lead times and more costs. Materials are more likely to be damaged or obsolete. Excess inventory actually can hide problems that need to be addressed.
Unnecessary movement- Any motions by production team members that do not add value to the process are unnecessary. Walking is one very common example of this waste.
Defects- This occurs when processes are not completed correctly the first time. The result is rework, scrap, and other additional costs.
In 2010, the Windsor team will work to reduce these wastes through the use of Kaizen, new equipment purchases, and capability improvements of existing equipment. These efforts will result in a higher level of product quality, on-time delivery, and greater value throughout the transaction cycle.