7 Wastes in PMs: Processing (Part 6 of 8)

Effort that adds no value from the customer’s viewpoint

The 5th of the 7 Wastes, Processing, can be one of the most difficult wastes to identify. (Over-Production, Transportation, Motion and Waiting are the first four and are discussed in our previous posts.)

Waste in processing occurs either when more work is done on a product than is needed to finish it, or when tools and equipment are used in the production process that are more precise, expensive, or complex than are required.  Some examples of over-processing might include using expensive legacy equipment where less complex equipment could be used, over-tight tolerances, multiple cleaning of parts, excessive paperwork and awkward tool or part design.  Processing waste is sometimes described as using a sledge hammer to crack a peanut.

Processing Waste in PMs:

  • PM Tasks performed by inappropriate or higher skill set than necessary. Policy, training, poor task instructions, subjective criteria, equipment design.
  • Excessive PM task time resulting from poor equipment design.
  • PM tasks performed and failures still occurring. Lack of "PM task to failure" analysis.
  • Excessive paperwork of work orders. Technology limitations, Crafts not using PC.

The next of the 7 Wastes in our series will be Inventory.

About the Author:

Ed Stanek, Jr. is President of LAI Reliability Systems, Inc.,  an expert consultancy specializing in Lean Maintenance Management techniques including PM Optimization, Work Management, Maintenance Metrics and Value Stream Mapping for Maintenance.  For more information, visit http://www.laireliability or call toll-free at 800-993-2828.

Click here to see the previous post, 7 Wastes in PMs: Waiting (Part 5 of 8)...

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