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Overprocessing Waste. An in-depth look at current processes should reveal where the improvement opportunities exist, although they may not be quick to eliminate. However, from a lean waste standpoint, overprocessing refers to manipulating and changing final products/services above and beyond what the customer expects and is willing to pay for.

Lean Consultants will often coach an organization to ‘put themselves in their customer’s shoes’, in other words, to see specifications and products through their customer’s eyes. This can seem a bit incongruous in a world where quality is prized and, well, better is perceived to always be better. First identified by Toyota’s Taiichi Ohno, the seven wastes include most of what value stream mapping reveals as non-value-adding activities. As with most other types of inefficiencies, some waste of overprocessing will be easily identifiable, while others will not be. Causes of Overprocessing Waste include: Poorly communicated customer specifications that leave doubt as to exact requirements Rework to meet product specifications or quality requirements Poorly planned work processes that cause extra steps along the …

In the office, workers who collaborate with each other often should be close together.

Of course, having data from your production process can help you to not only to uncover hidden waste but also to quantify obvious waste so that you can both assess costs of improvement and measure the results of progress. The second cause is lack of instructions or lack of clear specifications to direct production activity. The Worximity Smart Food Factory solution is a low-cost hardware system that can be up and running in a few hours combined with an easy and intuitive yet powerful analytics dashboard that provides fast ROI to start and a roadmap to full-on IIoT success.
Many factors can lead to Overprocessing Waste. The “Seven Wastes” is a key concept in lean manufacturing. Excess Processing also can include r, unning more analysis than is required to meet specifications, h, aving to adjust components after installation or o, Having reviewed our 8 Part Series on Waste in Lean Manufacturing you can now run an eight waste ‘learn to see’ audit on your own and likely produce significant value for your business. Excess Processing also can include running more analysis than is required to meet specifications, having to adjust components after installation or over engineering products. 7 Lean Wastes – Over Processing Machines operating slower or faster than necessary Equipment that uses more energy than needed Performing redundant tasks Doing things just because it’s the historical norm Cleaning things multiple times Paying meticulous attention to detail with no added benefit. The most common explanation given about overprocessing is that it is the act of doing extra, non-value added steps. The “over processing” waste is mostly about doing the job simply and efficiently, and only doing what adds value in the eyes of the customer. As with other types of waste, Overprocessing Waste can occur in the office as well as manufacturing areas. By looking at a final product for a customer in this way and mapping your own product vision more closely to theirs, you can gain insights into where excess processing may be occurring. Lean Consultants will also coach businesses to ‘Learn to See Waste’ and in fact undertaking Lean Manufacturing is sometimes also called ‘learning to see’. But adding to the product does not always add to its value. In the factory, material… This can seem a bit incongruous in a world where quality is prized and, well, better is perceived to always be better. The three main things to consider with waste of processing are whether or not the work is actually necessary, if it adds value … But there is far less commonly discussed nuance to overprocessing waste. Overprocessing leads to additional labor costs and material costs. The World’s Largest Distributor of Golf Cart Accessories and After-Market Parts. Sometimes, products that are excessively processed are highly complex and expensive and it can be difficult to clearly identify overprocessing. Additionally, excessive movement of people and equipment can lead to unnecessary work, greater wear and tear, and exhaustion. You are then able to work backwards through the entire process to root out overprocessing wherever it occurs.

Let’s look at a simple example: Let’s say a part is being produced to a specified tolerance and is well suited to the product in which it is used. Having reviewed our 8 Part Series on Waste in Lean Manufacturing you can now run an eight waste ‘learn to see’ audit on your own and likely produce significant value for your business. For example, printing out an e-mail for filing, or grinding a burr off a product after a cutting process. Ask Dave a Question or call (866) 714-8422, Your email address will not be published. The waste of overprocessing is caused when tasks, activities, or material is added to a product that does not meet the end customer’s requirements.

Engineers should also strive to define the most efficient processes on the simplest and least expensive equipment for the job.

In Lean terms, standardized work should be implemented for all processes to both specify and enforce the optimum manufacturing practices. Of course, having data from your production process can help you to not only to uncover. By using Lean Manufacturing, products are designed and fabricated using equipment and design methods that help to ensure products that exactly meet end customer requirements.
Tightening up the tolerance will make the manufacturing process more costly but may not change the performance of the product itself, therefore not increase value to the customer. But adding to the product does not always add to its value. Producing more detailed reports than necessary in order for one report to satisfy many users is one from of office overprocessing waste. | +1 770.368.4000  | 420 Technology Parkway, Suite 100 Peachtree Corners, Georgia 30092, The Seven Wastes – Part 4: Over-Processing. The eight wastes of lean manufacturing can be remembered with the acronym DOWNTIME: hbspt.cta._relativeUrls=true;hbspt.cta.load(3418759, 'ac6317d5-180d-4e2d-a74b-fcbcd2b915e5', {}); Read More: Types of Waste in Lean Manufacturing - Part 1 - Defects Waste, Types of Waste in Lean Manufacturing - Part 8 - Overprocessing Waste, Poorly communicated customer specifications that leave doubt as to exact requirements, Rework to meet product specifications or quality requirements, Poorly planned work processes that cause extra steps along the way, Including more components or material than necessary for the product to meet specifications, Delivering higher precision dimensional components than necessary. There are really two causes (and therefore two ‘cures’) for over-processing. Over seven weeks, I’m briefly discussing: Overproduction, Delay, Transporting, Over-Processing, Inventory, Motion, Defectives in the context of what manufacturers are concerned about today. A simple example of overprocessing waste is when a part of a product is highly polished using labor and machinery when it’s not a customer or product functionality requirement. This also includes using tools that are more precise, complex, or expensive than absolutely required. so that you can both assess costs of improvement and measure the results of progress. It is an extra step that adds cost but not value. At other times, a comparison of detailed customer specifications or the elimination of rework can eliminate overprocessing. Waste of Overprocessing. Inc. © 2020 All Rights Reserved. Your email address will not be published.

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