Table 4. Wastage analysis (analysis of... | Emerald Publishing

Table 4.

Wastage analysis (analysis of process waste from current and future VSM)

Process steps	Examples of waste	Causes	Corrective actions Generated from the Kaizen
1. Cutting	Muri: The operator in the cutting step was working a 10-h shift to meet the demand of the other process steps while achieving just 4 h of production time Overprocessing: No jig in place operator measuring material for every cut	Lack of material organisation and storage Equipment not set up for standardised work	Standard work and an extra operator were introduced to improve the flow 5S system set up with equipment
2. Grinding	Waiting: Significant production time was lost due to waiting for material from the cutting step	A bottleneck in cutting step	Standard work was implemented, and an extra operator in cutting reduced the bottleneck
3. Tacking	Waiting/motion/transport: Lost production time due to lack of tools -missing jigs and clamps Defects: Wrong tools used	Lack of correct equipment Operator error	5S system set up with new equipment. Poke Yoke introduced
4. Welding	Overburdened: welder 10-h shifts High defects – scrap levels	Bottleneck More resources required	Standard work was implemented, and a new welder was added to improve the flow Poke Yoke introduced
5. Cleaning	Waiting: on welding	Bottleneck from the previous station	Eliminated with the new welder
6. QC check	Overprocessing – manual steps printing, writing, scanning	Not automated	A new process with standard work and an Automated scanner introduced
7. Wrapping	Waiting on welding	Bottleneck	Eliminated with a new welder. Merged with QC check
8. Shipping	Transport/waiting/inventory of skids	Outgoing inventory build-up/no space/delays in getting on site	A just in time (JIT) daily delivery of skids was implemented (just as required on site)

Process steps	Examples of waste	Causes	Corrective actionsGenerated from the Kaizen
1. Cutting	Muri: The operator in the cutting step was working a 10-h shift to meet the demand of the other process steps while achieving just 4 h of production timeOverprocessing: No jig in place operator measuring material for every cut	Lack of material organisation and storageEquipment not set up for standardised work	Standard work and an extra operator were introduced to improve the flow5S system set up with equipment
2. Grinding	Waiting: Significant production time was lost due to waiting for material from the cutting step	A bottleneck in cutting step	Standard work was implemented, and an extra operator in cutting reduced the bottleneck
3. Tacking	Waiting/motion/transport:Lost production time due to lack of tools -missing jigs and clampsDefects: Wrong tools used	Lack of correct equipmentOperator error	5S system set up with new equipment.Poke Yoke introduced
4. Welding	Overburdened: welder10-h shiftsHigh defects – scrap levels	BottleneckMore resources required	Standard work was implemented, and a new welder was added to improve the flowPoke Yoke introduced
5. Cleaning	Waiting: on welding	Bottleneck from the previous station	Eliminated with the new welder
6. QC check	Overprocessing – manual steps printing, writing, scanning	Not automated	A new process with standard work and an Automated scanner introduced
7. Wrapping	Waiting on welding	Bottleneck	Eliminated with a new welder. Merged with QC check
8. Shipping	Transport/waiting/inventory of skids	Outgoing inventory build-up/no space/delays in getting on site	A just in time (JIT) daily delivery of skids was implemented (just as required on site)

Source: Authors’ own