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By George Sullivan

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Defect Production Waste Human errors invite defects and defects are the watershed for a long cascade of events. Customer complaints increase. “Wastology” ◾ 177 Rising customer complaints lead to beefed up inspection staff. This usually results in fewer complaints. However, the reduction in complaints does not in any way mean a reduction in defective goods (except shipped defectives). To reduce the occurrence of defects in the first place, we need to go all the way back to their original causes.

Of times Processing Lots No. of times No. of times Conveyance Distance Time No. of units Retention No. of times Lots Inspection After improvement No. of times No. of times Processing Lots No. of times Conveyance Distance Time No. of times No. : No. 26 Summary Chart of Flow Analysis. 25 are one of the simple analytical tools developed by conventional IE that can provide very useful results. However, most of IE’s other statistical tools take a lot of time and labor to achieve similarly effective results, and much of this work is usually done at a desk and away from the factory.

Do not use, “I know that job like the back of my hand,” as an excuse for ­filling out the table anywhere but in the factory. Look at the real situation in the factory as you fill out the table. ◾◾ Point 2: Everything that is not work (value-adding) must be counted as waste. Always look as critically as you can to distinguish work from movement as you observe the worker’s actions. Start by trying to identify the value-adding aspects of the operations. ◾◾ Point 3: Look for the nitty-gritty details.

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