Waste No. 6 - Waste of Defects

7 Waste of Lean Manufacturing series and today we talk about

Waste No. 6 - Waste of Defects

What it is?

1. Waste of correction that includes additional work implemented into the product.
2. Cause by unclear working instructions or procedure.
3. Such as unnecessarily of tolerance such as too tight that beyond machine capability to produce.
4. Inadequate training given to the operator.
5. Incapable of the machines.

How you over come it?

1. Poka Yoke can help in reducing or eliminating error produce by human.
2. Process that can be replace using automation can further assist operator in producing consistent product. 
3. Regular OJT (On Job Training), this is to instill operator knowledge of the work and upgrading skills.
4. Regular review the design of the product with value engineering or value analysis to identify opportunity of improvement.
5. Too many of over processing, Off-cut product can also lead to defects pile up and potential create mix of bad and good.

Hope above simple sharing can give you some of pointers to help your process to overcome the waste No.6 - Defects in Lean manufacturing.

By reducing defects you will improve the productivity and process efficiency and further reducing operating costs and eventually increase operating profit margin.

If you have more idea why not drops us in comment - Thanks!