7 Wastes Observation Form

Topic
7 Wastes, Overview of Lean, Lean Manufacturing, SMED Quick Changeover, Classic Kaizen

Summary
A Tool to be used to document, present, and analyze opportunities to eliminate waste in an area or department. This form is normally used during a workshop or a manager’s gemba walk.

Objectives
Observe, document, and classify wastes into specific categories that are present on your shopfloor, in your office, or in a process.

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Summary of Steps

1. Go to the office, process, or gemba (the place the work is done) that you want to document
2. Observe wastes and document into the correct categories or classifications of any wasteful activities identified
   1. Below is the definition for each classification of Waste:
      1. Defects
         • Making bad parts, having scrap, wrong information, and/or having to rework items
      2. Inventory
         • Any material in an area other than what is immediately needed for the next process/stage/step
      3. Processing
         • Activity that adds no value to the product or service from the viewpoint of the internal / external customer
      4. Waiting
         • Is created when material, information, machines, or approvals are not ready for us
      5. Motion
         • Any movement related to people that does not add value to the product or service
      6. Transportation
         • Moving material from one area to another area in the company
      7. Overproduction
         • Making more products than the next process (or internal/external customer) requires

Purchase

Included in:
Introduction to Lean Training Package
Lean MFG Workshop Training Package
SMED Quick Changeover Training Package
Classic Kaizen Workshop Package

Additional Resources
Lean Dictionary