M01 Preventing and Eliminating MUDA
M01 Preventing and Eliminating MUDA
Level-II
Based on March 2022, Curriculum Version 1
September, 2022
Addis Ababa, Ethiopia
Table of Contents
Acknowledgment ........................................................................................................................................... 4
Acronym ........................................................................................................................................................ 5
Introduction to module .................................................................................................................................. 6
Unit one: Prepare for work........................................................................................................................... 7
1.1 Job requirement work instructions ..................................................................................................... 8
1.2 OHS requirements for personal protection ....................................................................................... 10
1.2.1 Workplace hazards..................................................................................................................... 12
1.3 Selecting appropriate materials for work ......................................................................................... 14
1.4 Identifying and check Safety equipment and tools ............................................................................ 15
Self-Check: 1.1 ............................................................................................................................................ 16
Operation Sheet 1 ....................................................................................................................................... 17
LAP Test 1 ................................................................................................................................................... 18
Unit Two: Identify MUDA and problem .................................................................................................... 19
2.1 Identifying problem and prepare Plan for MUDA ............................................................................ 20
2.2 Discussing causes and effects of MUDA........................................................................................... 21
2.3 Using statistical tools and techniques list Kaizen problems ............................................................. 25
2.3.1 Techniques list Kaizen problems................................................................................................ 25
2.4 Analysing list and post on Kaizen Board .......................................................................................... 26
2.4.1 Process Kaizen ........................................................................................................................... 26
2.4.2 Using a Kaizen Board ................................................................................................................ 26
2.5 Identifying and measure relevant procedures on MUDA ................................................................. 27
Self-check: 2 ................................................................................................................................................ 28
Operation Sheet 2 ....................................................................................................................................... 29
LAP Test 2 ................................................................................................................................................... 30
Unit Three: Analyse causes of a problem ................................................................................................... 32
3.1 Listing all possible cause of problem................................................................................................ 32
3.2 Perform a Root Cause Analysis in 5 Steps ........................................................................................ 33
3.3 Possible cause of problem ................................................................................................................ 33
3.4 Analyzing cause using 4M1E ............................................................................................................ 34
3.5 Using creative idea generation eliminate critical root cause ........................................................... 35
3.5.1 Using Creativity to Solve Problems ........................................................................................... 35
3.6 Preparing action plan suggest solution ............................................................................................ 36
Self-check: 3 ................................................................................................................................................ 40
Operation sheet 3 ........................................................................................................................................ 41
LAP Test 3 ................................................................................................................................................... 42
Unit four: Eliminating MUDA and Assess effectiveness of the solution .................................................... 43
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4.1 Implementing Plan of MUDA ........................................................................................................... 44
4.1.1 Targets of Customer ................................................................................................................... 44
4.1.2 Targets of Manufacturer/Service provider................................................................................. 44
4.1.3 The concept of Cost .................................................................................................................... 44
4.1.4 Traditional Thinking of Price Setting ........................................................................................ 45
4.2 Adopting ten basic principles of eliminate waste/MUDA ................................................................. 47
4.2.1 Adopting the Necessary Attitude ................................................................................................ 47
4.2.2 Ten Basic Principles for Improvement ....................................................................................... 48
4.3 Using Tools based on OHS procedures ............................................................................................ 48
4.3.1 Eliminate the seven types of Wastes/Muda ................................................................................ 48
4.4 Identifying Tangible and intangible results ...................................................................................... 50
4.5 Compare various types of diagrams using tangible results .............................................................. 51
4.5.1 Plan and procedure for Waste/Muda Identification .................................................................. 51
4.6 Reporting gain improvements elimination of waste/MUDA ............................................................. 53
4.6.1 Some of the benefits of identifying and eliminating waste ......................................................... 53
Self-Check -4 ............................................................................................................................................... 54
Operation Sheet-4 ....................................................................................................................................... 55
LAP Test 4 ................................................................................................................................................. 56
Unit five: Preventing occurrence of wastes and sustain operation ........................................................... 57
5.1 Preparing prevention and implementation Plan of MUDA .............................................................. 58
5.1.1 Standardization .......................................................................................................................... 58
5.2 Preparing machines operation procedure ........................................................................................ 58
5.3 Preventing wastes/MUDA visual and auditory control methods ...................................................... 59
5.3.1 Visual and Auditory Controls .................................................................................................... 59
5.4 Creating waste-free workplace using 5W and 1H sheet ................................................................... 60
5.5 Updating practices Standard Operating Procedures (SOPs) ........................................................... 61
Self-check 5 ................................................................................................................................................. 62
Operation Sheet 2 ....................................................................................................................................... 63
Lap test 5 .................................................................................................................................................. 64
Reference..................................................................................................................................................... 65
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Acknowledgment
Ministry of Labor and Skills wish to extend thanks and appreciation to the many representatives
of TVET instructors and respective industry experts who donated their time and expertise to the
development of this Teaching, Training and Learning Materials (TTLM).
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Acronym
SI International Standard
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Introduction to module
In Automotive field of study; Prevent and Eliminate MUDA is one of important activity for the
mechanic for each activity. A worker to prevent and eliminate MUDA/wastes in his/her workplace
by applying scientific problem-solving techniques and tools to enhance quality, productivity and
other kaizen elements on continual basis.
This module contain how to identify and analyze problem causes of a problem, eliminate MUDA,
assess effectiveness of the solution and prevent occurrence of wastes and sustain operation.
This module is designed to meet the industry requirement under the automotive mechanics level
II occupational standard, particularly for the unit of competency: Prevent and Eliminate MUDA.
Module Instruction
For effective use this modules trainees are expected to follow the following module instruction:
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1. Unit one: Prepare for work
This unit is developed to provide you the necessary information regarding the following content
coverage and topics:
Job requirement work instructions
OHS requirements
Appropriate materials for work
Safety equipment and tools
This unit will also assist you to attain the learning outcomes stated in the cover page. Specifically,
upon completion of this learning guide, you will be able to:
Determining job requirement work instructions
OHS requirements for personal protection
Selecting appropriate materials for work
Identifying and check Safety equipment and tools
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1.1 Job requirement work instructions
A Job can be defined as:
A piece of work, especially a specific task done as part of the routine of one's occupation
or for an agreed price.
A post of employment; full-time or part-time position
Anything a person is expected or obliged to do; duty; responsibility
An affair, matter, occurrence, or state of affairs.
The material, project, assignment, etc., being worked upon.
The process or requirements, details, etc., of working.
The execution or performance of a task.
The requirements for a job vary according to the nature of the job itself. However, a certain work
ethic must be cultivated to succeed in any job and this is fundamental to an individual’s sense of
himself as a worker, as part of production relations and a fundamental economic being. The basic
requirements for a job remain the same no matter what the job is, where it is located or what
professional and educational qualifications are required for it. These are as follows:
Discipline: Nothing is possible without discipline. Any job requires a fundamental core of
discipline from the worker or the employee and this is a quality which is independent of age, post,
stature, job and so on. Discipline is absolutely indispensable and provides the impetus for work
that can be strenuous, repetitive, boring and even unsatisfactory at times.
Enthusiasm: Enthusiasm for work is also a pre-requisite for any job. An innate love for the job,
which in modern parlance is known as job satisfaction, is a core requirement for any job. The drive
to succeed, to innovate, to do well and to make one’s profession into one’s livelihood is a critical
drive which needs to be present in the employee or cultivated as soon as possible. No job, however
perfectly carried out, can evoke the feeling of satisfaction of a job well done without the instinct
for success.
Qualifications: This is a more material, tactile need for a job which can be conveyed through
degrees and certificates. However education is not limited to what is taught in colleges or
vocational training courses. It is the burning desire to learn more, to reach the depths of knowledge
about a particular field of interest, to complete the job and learn from it that marks the true
enthusiast and the truly learned.
Soft Skills: Soft skills include those skills which ensure that a job is executed well, and the
employee can carry himself in the proper manner too. For example, good and smooth
communication, computer skills, proficiency in language if needed, presentable appearance, the
ability to manage crises are all soft skills which are fundamentally important in any job and which
must be cultivated consciously.
Thus, the requirements of a job, though specific to it, cover also a general spectrum. These make
for better employees and better individuals.
Work Instruction
Information about the work
Describe what workers need to be able to do on the job
Work functions
Key activities of each work function
Performance indicators
Describe what task to be done or work roles in a certain occupation
Work instruction is a description of the specific tasks and activities within an organization. A work
instruction in a business will generally outline all of the different jobs needed for the operation of
the firm in great detail and is a key element to running a business smoothly.
In other words it is a document containing detailed instructions that specify exactly what steps to
follow to carry out an activity. It contains much more detail than a Procedure and is only created
if very detailed instructions are needed. For example, describing precisely how a Request for
Change record is created in the Change Management software support tool.
Many people confuse “procedures” with “work instructions”. In fact, most people write work
instructions and call them procedures. Knowing the differences of procedures vs work instructions
can help you understand the documentation process much better and, therefore, procedure
documentation.
Procedures describe a process, while a work instruction describes how to perform the conversion
itself. Process descriptions include details about the inputs, what conversion takes place (of inputs
into outputs), the outputs, and the feedback necessary to ensure consistent results. The PDCA
process approach (Plan, Do, Check, Act) is used to capture the relevant information.
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Questions that need to be answered in a procedure include:
OHS requirements are legislation/regulations/codes of practice and enterprise safety policies and
procedures. This may include protective clothing and equipment, use of tooling and equipment,
workplace environment and safety, handling of material, use of fire-fighting equipment, enterprise
first aid, hazard control and hazardous materials and substances.
Occupational safety and health (OSH) also commonly referred to as occupational health and safety
(OHS) or workplace health and safety (WHS) is an area concerned with the safety, health and
welfare of people engaged in work or employment. The goals of occupational safety and health
programs include fostering a safe and healthy work environment. OSH may also protect co-
workers, family members, employers, customers, and many others who might be affected by the
workplace environment. In the United States the term occupational health and safety is referred to
as occupational health and occupational and non-occupational safety and includes safety for
activities outside work.
Occupational safety and health can be important for moral, legal, and financial reasons. In
common-law jurisdictions, employers have a common law duty (reflecting an underlying moral
obligation) to take reasonable care for the safety of their employees. Statute law may build upon
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this to impose additional general duties, introduce specific duties and create government bodies
with powers to regulate workplace safety issues: details of this will vary from jurisdiction to
jurisdiction. Good OSH practices can also reduce employee injury and illness related costs,
including medical care, sick leave and disability benefit costs.
As defined by the World Health Organization (WHO) "occupational health deals with all aspects
of health and safety in the workplace and has a strong focus on primary prevention of hazards."
Health has been defined as "a state of complete physical, mental and social well-being and not
merely the absence of disease or infirmity. Occupational health is a multidisciplinary field of
healthcare concerned with enabling an individual to undertake their occupation, in the way that
causes least harm to their health. It contrasts, for example, with the promotion of health and safety
at work, which is concerned with preventing harm from any incidental hazards, arising in the
workplace..
The definition reads: "The main focus in occupational health is on three different objectives:
Joint ILO/WHO Committee on Occupational Health: those in the field of occupational health come
from a wide range of disciplines and professions including medicine, psychology, epidemiology,
physiotherapy and rehabilitation, occupational, occupational medicine, human factors and
ergonomics, and many others. Professionals advise on a broad range of occupational health
matters. These include how to avoid particular pre-existing conditions causing a problem in the
occupation, correct posture for the work, frequency of rest breaks, preventative action that can be
undertaken, and so forth.
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Occupational health should aim at: the promotion and maintenance of the highest degree of
physical, mental and social well-being of workers in all occupations; the prevention amongst
workers of departures from health caused by their working conditions; the protection of workers
in their employment from risks resulting from factors adverse to health; the placing and
maintenance of the worker in an occupational environment adapted to his physiological and
psychological capabilities; and, to summarize, the adaptation of work to man and of each man to
his job.
Physical hazards are a common source of injuries in many industries. They are perhaps
unavoidable in certain industries, such as construction and mining, but over time people have
developed safety methods and procedures to manage the risks of physical danger in the workplace.
Employment of children may pose special problems. Falls are a common cause of occupational
injuries and fatalities, especially in construction, extraction, transportation, healthcare, and
building cleaning and maintenance.
An engineering workshop specializing in the fabrication and welding of components has to follow
the Personal Protective Equipment (PPE) at work regulations 1992. It is an employer’s/workers
duty to provide ‘all equipment (including clothing affording protection against the weather) which
is intended to be worn or held by a person at work which protects him against one or more risks to
his health and safety’. In a fabrication and welding workshop an employer would be required to
provide face and eye protection, safety footwear, overalls and other necessary PPE.
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The transportation sector bears many risks for the health of commercial drivers, too, for example
from vibration, long periods of sitting, work stress and exhaustion. These problems occur in
Europe but in other parts of the world the situation is even worse. More drivers die in accidents
due to security defects in vehicles. Long waiting times at borders cause that drivers are away from
home and family much longer and even increase the risk of HIV infections.
Confined spaces also present a work hazard. The National Institute of Occupational Safety and
Health defines "confined space" as having limited openings for entry and exit and unfavourable
natural ventilation, and which is not intended for continuous employee occupancy. Spaces of this
kind can include storage tanks, ship compartments, sewers, and pipelines. Confined spaces can
pose a hazard not just to workers, but also to people who try to rescue them.
Noise also presents a fairly common workplace hazard: occupational hearing loss is the most
common work-related injury in the United States, with 22 million workers exposed to hazardous
noise levels at work and an estimated $242 million spent annually on worker's compensation for
hearing loss disability. Noise is not the only source of occupational hearing loss; exposure to
chemicals such as aromatic solvents and metals including lead, arsenic, and mercury can also cause
hearing loss.
Electricity poses a danger to many workers. Electrical injuries can be divided into four types: fatal
electrocution, electric shock, burns, and falls caused by contact with electric energy
Vibrating machinery, lighting, and air pressure (high or low) can also cause work-related illness
and injury. Asphyxiation is another potential work hazard in certain situations. Musculoskeletal
are avoided by the employment of good ergonomic design and the reduction of repeated strenuous
movements or lifts. Ionizing (alpha, beta, gamma, X, neutron), and non-ionizing radiation
(microwave, intense IR, RF, UV, laser at visible and non-visible wavelengths), can also be a potent
hazard
In Victoria, workplace health and safety is governed by a system of laws, regulations and
compliance codes which set out the responsibilities of employers and workers to ensure that safety
is maintained at work.
B. Act of OHS
The Occupational Health and Safety Act 2004 (the Act) is the cornerstone of legislative and
administrative measures to improve occupational health and safety in Victoria.
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The Act sets out the key principles, duties and rights in relation to occupational health and safety.
The general nature of the duties imposed by the Act means that they cover a very wide variety of
circumstances, do not readily date and provide considerable flexibility for a duty holder to
determine what needs to be done to comply.
C. Regulations of OHS
The Occupational Health and Safety Regulations 2007 are made under the Act. They specify the
ways duties imposed by the Act must be performed, or prescribe procedural or administrative
matters to support the Act, such as requiring licenses for specific activities, keeping records, or
notifying certain matters.
D. Guidance of OHS
Effective OHS regulation requires that Work Safe provides clear, accessible advice and guidance
about what constitutes compliance with the Act and Regulations. This can be achieved through
Compliance Codes, Work Safe Positions and non-statutory guidance ("the OHS compliance
framework"). For a detailed explanation of the OHS compliance framework, see the Victorian
Occupational Health and Safety Compliance Framework Handbook.
E. Policy of OHS
Not every term in the legislation is defined or explained in detail. Also, sometimes new
circumstances arise (like increases in non-standard forms of employment, such as casual, labour
hire and contract work, or completely new industries with new technologies which produce new
hazards and risks) which could potentially impact on the reach of the law, or its effective
administration by Work Safe. Therefore, from time to time Work Safe must make decisions about
how it will interpret something that is referred to in legislation, or act on a particular issue, to
ensure clarity. In these circumstances, Work Safe will develop a policy. A policy is a statement of
what Work Safe understands something to mean, or what Work Safe will do in certain.
Tools and Equipment are required to identify and measure Waste/Muda in work stations. The
following are some tools and equipment used to identify and measure Waste/Muda:
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Photo Camera
Video Camera
Calculator
Tools and Equipment for Waste/Muda Identification Tape/Meter Stop watch, Photo Camera Video
Camera Calculator
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Self-Check: 1.1
Name…………………………….……………ID…………………Date…………..
Directions:
Instruction I choose the best answer
1. __________The Occupational Health and Safety Regulations 2007 are made under the Act
A. Regulations B. Guidance C. Policy D.ALL
2. ___________Effective OHS regulation requires that Work Safe provides clear, accessible
advice and guidance
3. ___________ include those skills which ensure that a job is executed well, and the employee
can carry himself in the proper manner too
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Operation Sheet 1
Prepare tools and equipment for identification and measuring Muda.
Procedures
1. Discuss and plan to prepare tools and equipment for Muda identification.
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LAP Test 1
Practical Demonstration
Name: _________________________ Date: ________
Time started: ________________________ Time finished: _______
Instructions: Given necessary templates, workshop, tools and materials you are required to
perform the following tasks.
Task 1: Identify and prepare tools and equipment for measuring and identification of Muda.
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2. Unit Two: Identify MUDA and problem
This unit is developed to provide you the necessary information regarding the following content
coverage and topics:
Identify problem and prepare Plan for MUDA
Causes and effects of MUDA
Statistical tools and techniques list
List and post on Kaizen Board
Relevant procedures on MUDA
This unit will also assist you to attain the learning outcomes stated in the cover page. Specifically,
upon completion of this learning guide, you will be able to:
Identifying problem and prepare Plan for MUDA
Discussing causes and effects of MUDA
Using statistical tools and techniques list Kaizen problems
Analyzing list and post on Kaizen Board
Identifying and measure relevant procedures on MUDA
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2.1 Identifying problem and prepare Plan for MUDA
Motion
Do you move unnecessarily during a process or activity? Ever make 3 trips back into the house for
things you forgot before finally leaving?
Transportation
Do you move materials or supplies unnecessarily? This isn’t about you moving this is about
moving stuff. I’ve walked miles in the kitchen carrying ingredients back and forth; maybe better
organization could cut down on how much we have to carry stuff?
Inventory
Having too much, or too little of supplies. Sticking with the kitchen theme, how much does it cost
in time, energy and gas when you have to run out at the last minute for missing ingredient? On the
other end buying too much of anything is a waste as well. I’ve still got dozens of pipe fittings I
purchased 8 years ago (just in case!) during a kitchen renovation.
Over-processing
Doing more than really necessary. Scrubbing the same spot after it’s already clean, repetitive
mouse clicks because we don’t know the computer’s shortcut commands, or too much packaging
peanuts and such for a non-fragile item are all examples of over-processing.
Rework
As the saying goes, “if you don’t have time to do it right the first time, when will you have time
to do it over.” – John Wooden. Rework is just that, having to do anything a second time because
it was unacceptable the first. Be it cleaning, repairing, filling out forms a second time we all
experience the pain and frustration of rework.
Time
The most obvious to most of us, waiting for another person company or process before we can
move forward is a huge waste. Waiting for the computer to finish processing a page, waiting at the
doctor’s office long past your appointed time, or waiting in line at the local grocery store costs us
all. The more inefficient others are, the less efficient we can be.
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2.2 Discussing causes and effects of MUDA
2.2.1 Causes of Muda of Overproduction
Large-lot production
Anticipatory production (producing product in advance of demand)
Inability to achieve short changeover times with the large equipment used in mass
production systems • Creating enough stock to replace the number of defective parts
produced
Overstaffing or too much equipment
Waste of space
Needs for inspection, and transportation
Expansion of working fund
Shelf life may expire
It ties up cash
2.2.3 Causes of Muda of motion
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Isolated operations
Low employee morale
Poor work layout
Lack of training
Undeveloped skill
2.2.4 Causes of Muda of Conveyance/Transportation
Poor layout • Shish-skilled workers
Sitting to perform operations
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Effects of Muda of Defect making
Cash – A 9th form of waste appropriate to personal financial growth is just plain cash. How many
times have you purchased a product or service but never used it? Have you ever bought food that
was never eaten, clothes that were never worn or software that was never used?
By training yourself to see the Muda you will find that it is easier to save a dollar than to make a
dollar. It’s that recognition, which in part, prompted this blog.
There are probably other ways we can categorize waste that are not “official” according to Lean
Management. Where else do we have waste in our lives? Please contribute if you can add to the
list.
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Classification of waste
A number of methods for classification of waste have emerged. Here are some of them:-
The 3MU’s
5M+Q+S
We should not force hard work on Employees in the name of productivity improvement
• Mental and physical overburden on operators, and overburden on production machinery
Mura
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Relationship between the 3 M’s
• Usually Mura creates Muri which in turn lead to generation of Muda
5S. During a Kaizen event, there will be questions regarding quality management that need
to be answered.
Value Stream Mapping. To study how the value of a product flows through a process,
teams use value stream mapping (VSM).
Fishbone Diagram.
Pareto Analysis.
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Gemba: means the real place. Often managers and supervisors can get valuable
information by actually going down to the production line and talking with employees.
Gemba is often used in the form of Gemba walks, which are scheduled walks for managers
and supervisors observe processes up close and talk with frontline employees.
Jishuken: can be translated into an autonomous study groups or self-study. This concept
encouragers managers to be more directly involved and learn about the processes they are
responsible for and how they can work to improve them.
5 Whys: This is an important tool when it comes to identifying the root cause of an issue.
It is difficult to make an impactful change in the workplace if the root cause has yet to be
considered. The 5 Whys is exactly like the name implies; after a problem arises you should
ask yourself why five times.
Value Stream Mapping: Mapping out processes and streams in a facility can be very
beneficial for a business practicing Kaizen. These maps are usually hand-drawn and
include a diagram of materials moving through the different areas of the workplace. It is
important to remember these are just a few tools that fall under the umbrella of Kaizen.!
Process Kaizen happens at the individual / team level, taking small, targeted steps to improve
efficiency, productivity, communication, and transparency. Because it is simply the process of
making incremental improvements, process Kaizen is accessible to anyone looking to improve
their performance, regardless of whether their organization is undergoing a Lean initiative.
If the following scenario sounds familiar to you, a Kaizen board might help: You have a super-
productive team meeting, one where everyone contributed awesome ideas for working smarter and
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getting more done. A week or two goes by… and none of the ideas have been implemented. You
have another meeting to discuss the ideas, and everyone gets energized once more – but once
again, nothing actually gets done.
This is where a Kaizen board becomes useful. It’s difficult to make time and devote energy to
work that isn’t treated like work, but rather, a side project. Using a Kaizen board at the team or
organizational levels can help turn good ideas into actionable cards, which the group collectively
manages. As long as the team (or organization) commits to reviewing the board as a group (and
prioritizing the work alongside other work), a Kaizen board can make your improvement ideas a
reality.
A. Inventory
This waste is materials that aren’t used or finished goods that haven’t been sold. Inventory can
take up a lot of real estate and can be costly to store. Finished goods that are sitting around can
deteriorate or expire if it’s a perishable good. Work in process inventory can turn into waste if it
was scrapped or if it isn’t actively used in production.
B. Transportation
This type of waste represents the unnecessary steps between the production processes. For
example, during the transportation of materials from one location to another, is there any
movement that can be eliminated or reduced? Additionally, it’s considered Muda if the load of the
vehicle used to transport these materials is under capacity. Another example is documentation.
Documentation includes a lot of steps such as filling out paperwork, signing documents, passing
these documents to different departments, etc. There are a lot of tools available that can make this
process more efficient such as using software and applications.
C. Motion
Unlike transportation which is between the processes, motion is a waste when there is
unnecessary movement within the process. Transportation is about the movement of product and
materials while motion is waste from people and equipment. This is the waste that affects the
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people working on the product and the machines used during production. Are the workers doing
more steps than necessary or were any injured during their shift? Did the equipment experience
any downtime?
D. Waiting
This waste is generated when there are idle tasks. Sometimes there is no remedy but to wait. For
example, workers taking breaks in between tasks. Another example, when there is a queue for the
next process of the production line due to the equipment’s capacity to finish the current load.
E. Over processing
This waste is generated when more work is done to finish a task or output. A method to eliminate
this Muda is to determine the root cause of the additional steps or processes conducted. Is the over
processing caused by human error or is there any equipment and machine that needs to be
maintained or repaired?
F. Overproduction
It’s wasteful to produce more than what can be shipped out and delivered. Overproduction also
affects other Muda categories such as inventory and transportation.
G. Defects
It’s a waste when a finished product has defects. Most defective products are scrapped and thrown
away which increases costs and leads to reproduction. Two ways to reduce defects is to conduct
product testing and set routine inspections during the production process.
Self-check: 2
Name………………………………… ID………………………… Date…….
Directions:
Instruction I choose the best answer
1._____________ it’s a waste when a finished product has defects. Most defective products are
scrapped and thrown.
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A. Defects B. Overproduction C Over processing D. Wait
4 ___________ is about the movement of product and materials while motion is waste from people
and equipment.
Operation Sheet 2
Identify MUDA and problem
1. Mura,
2. Muri and
3. Muda
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Step3 Recognize the actual capacity of each worker/machine in the process.
Step5 Explain the existence of Mura, Muri and Muda on each machine/worker.
LAP Test 2
Practical Demonstration
Given necessary templates, workshop, tools and materials you are required to perform the
following tasks within 30 min.
Task 1. In the given operation, identify the three categories of operation, measure their
magnitude in terms of time and compare them.
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Task 2. In the given workplace and check the existence of Mura, Muri and Muda in each process
and list out them.
Task 3. Using appropriate method identify the seven types of Muda in the workplace.
Task 4: Using the given template list out the types of Muda identified and analyze their causes
and measure their magnitude.
This unit is developed to provide you the necessary information regarding the following content
coverage and topics:
All possible cause of problem
Cause using 4M1E
Creative idea generation eliminate critical root cause
Action plan suggest solution
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This unit will also assist you to attain the learning outcomes stated in the cover page. Specifically,
upon completion of this learning guide, you will be able to:
Listing all possible cause of problem
Analyzing cause using 4M1E
Using creative idea generation eliminate critical root cause
Preparing action plan suggest solution
Problems can have a single underlying cause. One very effective approach to effective problem
solving is Root Cause Analysis (RCA). RCA is one of the most widely used tools/techniques for
detecting issues.
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The power of Root Cause Analysis lies in its ability to analyze the situation and pinpoint the root
of the problems – rather than treating the symptoms. This systematic approach focuses on
identifying both, active problems and latent errors, which cause adverse situations and events. It
focuses on identifying the main cause of the problem.
And to be clear, “problem solving” and “improvement” are learning processes. If you didn't learn,
you didn't solve the problem, and you didn't improve anything
1.Define the problem. Analyze what you see happening, and identify the precise symptoms
so that you can form a problem statement.
2.Gather data.
3.Identify causal factors.
4.Determine the root cause(s).
5.Recommend and implement solution
The identification and selection of appropriate options for addressing a problem should be guided
by an understanding of its cause. Such insights may also lead to the original framing choice being
changed. Often the causes of health systems problems are complex and uncertain and it may be
more appropriate to consider underlying factors without attributing causation. The process of
clarifying the cause or underlying factors is unlikely to be simple or linear. And although it may
be possible to reduce uncertainty about the cause, it may be equally or more important to clarify
uncertainty about the cause. Strategies for clarifying the cause of health system problems include
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using either broader or more specific frameworks, brainstorming, reviewing relevant research
evidence, and interviews with key informants.
Cause and effect analysis concerned Man, Machine, Material, Method and Environment (4M1E)
which were applied in this process . It was revealed that the number of tentative causes was 12
factors as shown in Table 2. These factors were used for further analyzing the relationship between
cause and related effect using the cause and effect matrix.
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3.5 Using creative idea generation eliminate critical root cause
Entrepreneurs are faced with solving many problems as they develop their ideas for filling gaps,
whether those opportunities involve establishing a new company or starting a new enterprise
within an existing company. Some of these problems include staffing, hiring and managing
employees, handling legal compliance, funding, marketing, and paying taxes. Beyond the
mundane activities listed, the entrepreneur, or the team that the entrepreneur puts in place, is
indispensable in maintaining the ongoing creativity behind the product line or service offered.
Innovation and creativity in the business are necessary to expand the product line or develop a
groundbreaking service.
It is not necessary for the entrepreneur to feel isolated when it comes to finding creative solutions
to a problem. There are societies, tools, and new methods available to spur the creativity of the
entrepreneur that will further support the success and expansion of a new enterprise.14 Learning
and using entrepreneurial methods to solve problems alleviates the stress many startup owners
feel. The entrepreneur’s creativity will increase using collaborative methodologies. Some
entrepreneurial collaborative methodologies include crowdsourcing, brainstorming,
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storyboarding, and conducting quick online surveys to test ideas and concepts, and team creativity
activities.
An action plan consists of seven steps: setting objectives, assessing the objectives, identifying
action required to meet the objectives, working out how to evaluate the activity, agreeing a time-
frame for action, identifying resources (human, financial and technical), finalizing the plan, and
evaluating the results.
1. Set objectives
You need to identify clear objectives that will guide your work to achieve the resource center’s
aims. Objectives need to be achievable - do not be over-ambitious. They need to be measurable
(for example, a certain number of activities carried out within a certain period), so that you can
know whether you have achieved them.
Ask yourself:
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Assessment helps to determine whether or not the objective is appropriate. It may result in
confirming the objective, abandoning it or revising it. Ask yourself:
Is the objective compatible with the resource center’s aims and objectives?
Are the necessary resources (funds, equipment, staff) available to reach this objective? If
not, are they obtainable?
What problems might arise in working to achieve this objective?
Example of resources needed to carry out the objective: staff time, relevant materials in
the resource center or obtainable from elsewhere, stationery, photocopier, postage.
Example of revised objective: To produce and distribute an information pack on malaria
diagnosis and management to 20 health clinics and training institutions within the next
six months.
A series of tasks needs to be identified for the objectives to be achieved. List these as steps.
Ask yourself:
1. Plan the content of the information pack and decide how to distribute the packs, in
consultation with other staff and users.
2. Calculate costs and staff time, and make sure that funds and time are available.
3. Allocate responsibilities.
4. Gather information for the pack (search resource center, contact other organizations).
5. Request permission from publishers to photocopy material.
6. Photocopy material and prepare packs.
7. Distribute packs.
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How will we know whether we have achieved our objectives
Example:
Contact five clinics to see whether they have received the packs.
Include an evaluation form in the pack, asking health workers whether the
information has improved their knowledge, how they have used the information,
and how future packs could be improved. Assess the feedback from the forms.
1. Plan the content of the information pack, including evaluation forms, and decide how to
distribute the packs, in consultation with other staff and users.
2. Calculate costs and staff time, and make sure that funds and time are available.
3. Allocate responsibilities.
4. Gather information for the pack (search resource centre, contact other organisations).
5. Request permission from publishers to photocopy material.
6. Prepare evaluation forms.
7. Photocopy material, prepare packs.
8. Distribute packs.
9. Contact clinics to see if they have received packs.
10. Revise plans for distributing packs if they have not reached some clinics.
11. Assess the feedback from the evaluation forms and use it to plan future work.
As you identify each task, work out how long it will take and when it needs to be done. This will
help you to see whether your action plan is on schedule or whether you need to modify the
schedule.
Ask yourself:
What is the actual time required for each individual task? (Be careful not to under-
estimate)
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When will each step be completed?
Example: Total of 18 days over a three-month period
6. Assess the action plan
Ask yourself:
How will you know whether the individual tasks have been achieved?
Have you allowed for possible interruptions?
Have you tried to do too much or too little?
An action plan must be realistic if it is to work. It is easy to over-estimate what you can do, leading
to disappointment and failure. For example:
1. Leaflets that you had planned to include in the pack may have run out and need to be
reprinted. Can you substitute something else, or will you need to arrange for them to be
reprinted before you can finish preparing the packs?
2. The member of staff preparing the pack will take annual leave for six weeks during the
period in which the pack was planned to be prepared. Can you re-schedule the work, or can
someone else do it?
Revise the action plan. Obtain feedback and comments from colleagues, and revise it again if
necessary.
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Self-check: 3
Name…………………………………………….……..……ID……………………
Date………….
Directions:
Instruction I choose the best answer
1. ___________Decision tree analysis is the process of drawing a decision tree, which is a
graphic representation of various alternative
A. Decision tree B. Cause C. effect D.ALL
2.__________can be an important trait of an entrepreneur. In that discussion, we learned about
creativity’s role in innovation.
A. Creativity B. Decision tree C. effect D.ALL
3. ____________As you identify each task, work out how long it will take and when it needs to
be done.
A. Agree a time frame B. Assess the action plan C. Assess the objectives D. None
4. ____________ identifies clear objectives that will guide your work to achieve the resource
centre’s aims.
A. Agree a time frame B. Assess the action plan C. Assess the objectives D. None
5 _____________Assessment helps to determine whether or not the objective is appropriate
A. Agree a time frame B. Assess the action plan C. Assess the objectives D. None
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Operation sheet 3
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LAP Test 3
Practical Demonstration
Instructions: Given necessary templates, workshop, tools and materials you are required to
perform the following tasks within 1 hours.
Task 1: After confirming the result, prepare a new standard procedure that is capable of preventing
recurrence of Muda eliminated.
Task 2: Prepare action plan to implement and follow up the standard procedure using the given
template.
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4. Unit four: Eliminating MUDA and Assess effectiveness of the solution
This unit is developed to provide you the necessary information regarding the following content
coverage and topics:
This unit is developed to provide you the necessary information regarding the following content
coverage and topics:
Plan of MUDA
Ten basic principles of eliminate waste/MUDA
Tools based on OHS procedures
Tangible and intangible results
Types of diagrams using tangible results
Improvements elimination of waste/MUDA
This unit will also assist you to attain the learning outcomes stated in the cover page. Specifically,
upon completion of this learning guide, you will be able to:
Implementing Plan of MUDA
Adopting ten basic principles of eliminate waste/MUDA
Using Tools based on OHS procedures
Identifying Tangible and intangible results
Comparing various types of diagrams using tangible results
Reporting gain improvements elimination of waste/MUDA
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4.1 Implementing Plan of MUDA
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Sales price= (manufacturing or service delivery)cost + profit
4.1.4 Traditional Thinking of Price Setting
Manufacturers/service providers, who want to set selling price above the market price, customers
will not be willing to buy their products/services.
Waste/Muda is any activity which consumes resources, such as money, time, energy, materials,
etc, that does not create value and can be eliminated.
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Value is defined by the next customer (Know your Customer’s Need). The next process is your customer.
The activity/effect exactly what the next customer needs is value adding activity. •
Part of an operation that adds value to make parts and products or deliver service. In other words,
it is part of the operation that the customer exactly needs / willing to pay for.
Part of operation that adds no value but cannot be avoided rather it can be reduced.
1. ”Muda‟
It is anything unnecessary in operation that affects the quality of the product/service, productivity,
delivery time and also production cost. Muda can be eliminated immediately.
Example
Operation:-To staple two papers using a stapler where the work place is disorganized.
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• Stapler
• Staples
First you must adopt an attitude that supports your ability to see waste. Waste is hard enough to
find when you want to find it; if you don’t want to find it, or if your response to find it is denial or
resistance, then it will never be possible for you to root out waste and make your work environment
stress free.
It is very important that you understand that one purpose of discovering waste is to take the
frustration out of your work.
Many people will resist see the waste in their work. Just don’t let it be you. You may hear yourself
or others saying things like: “Let’s not fix what is not broken.” “Can’t we live well enough alone?”
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“This is just another attempt to make us work harder for the same amount of money.” “It looks
good on paper, but it will never work on the floor.” “We tried that twenty years ago. It didn’t work
then; it won’t work now.” “That is not my job.” And so on.
You know the lines. You have probably said one or two of them at one time or another. We all
have. Resistance is normal. Just don’t let it keep you from learning to see the waste in your work.
In the end, you are the one who suffers most from the results of waste.
In order to balance capacity and load without overproducing, you must implement the advanced
methods of lean production:
Full work
Line balancing Pull production using Kanban
Quick-changeover operations.
Level production - small-lot, mixed production.
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U-shaped manufacturing cells, layout of equipment by process instead of operation.
Production leveling
Regulating the flow of production
Pull production using Kanban
Quick changeover operations
Where as many kinds of movement may be unnecessary, work is the movement you do to add
value to the product. Movement that does not add value is waste. Find ways to reduce the amount
of movement to do your value added work. Start by looking at the movement of your feet, then
your hips, shoulders, arms, hands and fingers.
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How to Eliminate Defect Wastes
Standard operations
Mistake-proofing devices
Full-lot inspection
Building quality in at each process
Flow production
Elimination of the need to pick up and set down work pieces
To reduce defects, their root cause must be found. Inspection that only sorts out the defective parts
is not a solution to defective waste; it is actually one of the major defectrelated wastes. Until you
initiate back-to-the-source inspection and build quality into every process through standardization,
the effects of defects will continue to disrupt the flow of goods and decrease productivity.
How to Eliminate Processing Wastes Improvement of jigs using
More appropriate process design automation
Review of operations Thorough standardization
Promotion of value analysis(VA) and value engineering(VE) techniques
How to Eliminate Defect Wastes
Standard operations Building quality in at each process
Mistake-proofing devices Flow production
Full-lot inspection
Then an assessment is carried out to see whether the impediments have been overcome or to what
extent the initial objectives have been met. It is carried out together with evaluation for further
improvement of the work. The Circle identifies the tangible and intangible results, verifies them
using data, and compares them with the initial goal. Tangible results are results targeted through
changes in processes, whereas intangible results are those in areas such as improvement in
employee learning skills and education. If the results do not meet the goal, then the Circle needs
to return to previous stages and reexamine the processes.
Tangible results are those that can be quantified, like when a defect rate is reduced by a certain
percent.
Intangible results on the other hand are those that are qualitative, like when teamwork among the
members is improved.
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The Circle must be able to establish at this point that the project gains also bring them direct
personal benefit. Therefore, a very important question that each QC Circle must answer is “What
is in it for me?” By answering this question, the members realize that they themselves, in addition
to the company, benefit from the project, which induces personal satisfaction as well as a sense of
achievement. This sense of achievement is the most important intangible result of QC Circle
activities. Take, for example, a case in which a defect rate is reduced by 90 percent. Obviously this
is good for the customer, and what is good for the customer is good for the company, but how is it
good for the Circle members? A member who is sold on the QC Circle philosophy will say, “It is
good for me because now I can be proud of my work, whereas before, I was ashamed of the
defective parts that I was making.”
1. Verify results
The QC Circle verifies the results over time. For instance, has the 90 percent reduction in defects
been sustained over a period of two weeks, over a month, over a quarter? Is improved teamwork
manifested in all activities at the workplace or only during QC Circle–related activities?
The QC Circle may achieve some results but these must be compared with the goal set in stage 3
step 4. Various types of diagrams can be used, but accurate comparisons cannot be made between
diagrams of the different types—that is, the same type must be used consistently.
It is not easy to find waste when you look at the production line or the warehouse or an operation.
If you have never been involved in improvement activities you will find it even harder to discover
waste that may be right in front of you. Waste is everywhere, in every operation; it is so common
and you are so used to it that it is hard to see
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Shop layout analysis and Process flow analysis
• There are several tools you can use to analyze current conditions of shop layout and process flow
quickly and effectively. We will describe some of them.
The Arrow Diagram focuses on the flow of goods to discover waste.(Arrow diagrams have recently
been renamed value stream maps.) We include here a simple method for creating an arrow diagram
to get a good understanding of your production process and to see where the waste exists in your
workplace.
The factors to be identified in your arrow diagram are retention, conveyance, processing and
inspection. There are specific symbols you use to indicate each of these aspects of a production
process as indicated below
2. Select the product to be analyzed- You can do a product/quantity (PQ) analysis to compare
products and quantity. Choose products with a large output and those with many production
problems as starting points for your analysis of current conditions using the arrow diagram.
3. Prepare a factory layout diagram- Include the entire factory layout, indicating the position of
machines, worktables and other equipment. Store the original in a safe place so that you can make
a copy of it each time you want to analyze another product line.
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4. Make the arrow diagram- Do this on the factory floor. Use the symbols below to show the
different types of activities that occur. The map will make the waste more obvious to you and your
team than when you are simply standing on the factory floor observing standard operations.
Connect the symbols with lines that show the direction of the flow and the sequence of product
through each operation. Create other symbols as you need to. At all conveyance points, note the
conveyance distance and type of conveyance. At all retention points, note average work-in- process
inventory.
1. Increased job satisfaction- No longer will you spend hours looking for missing tools, waiting
for materials to arrive, walking around piles of inventory, lifting and setting down heavy parts
or tools, working in unsafe conditions and all the other things you have to do that are not
essential to your job. The frustrating non-value-added aspects of your job will disappear and
what you are trained to do and enjoy doing will be the major part of how you spend your time.
2. Contributing to improvement- Your ideas about how to improve your job will be listened to
and you will participate in taking the frustration out of the workplace. Part of your job will be
to find root causes and to create solutions that last. You will not have to make short-term fixes
or live with someone short-term fixes that no longer solves the problems you face.
There is no question that when production waste is rooted out everyone is happier. The flow of
materials creates a hum in the workplace: a rhythm of the flow of materials from supplier to
customer emerges as the value-added processes are freed up to operate at the rate of customer
demand.
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Self-Check -4
Directions:
Answer all the questions listed below. Use the Answer sheet provided in the next page:
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Operation Sheet-4
Operation title: Ways of effective Waste/Muda identification
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LAP Test 4
Practical Demonstration
Name: _____________________________ Date: ________________
Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates, tools and materials you are required to perform the
following tasks within --- hour.
Task 1: In the given operation, identify the three categories of operation, measure their
magnitude in terms of time and compare them.
Task 2: In the given workplace and check the existence of Mura, Muri and Muda in each
process and list out them.
Task 3: Using appropriate method identify the seven types of Muda in the workplace.
Task 4: Using the given template list out the types of Muda identified and analyze their
causes and measure their magnitude.
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Unit five: Preventing occurrence of wastes and sustain operation
This unit to provide you the necessary information regarding the following content coverage and
topics:
Prevention and implementation Plan of MUDA
Machines operation procedure
Wastes/MUDA visual and auditory control methods
Waste-free workplace using 5W and 1H sheet
This guide will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:
Preparing prevention and implementation Plan of MUDA
Preforming machines operation procedure
Preventing wastes/MUDA visual and auditory control methods
Creating waste-free workplace using 5W and 1H sheet
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5.1 Preparing prevention and implementation Plan of MUDA
We have discussed how you discover waste and what to do to remove it; but it doesn’t end there.
Unfortunately, problems always crop up, and we prevent them from becoming sources of waste
we will be right back where we started in no time at all. That is one reason why one of the very
first things mentioned about discovering waste adopting the right attitude. If everyone is paying
attention to keeping waste from taking hold, then you have a good chance of sustaining production
flow. There are four important methods you can use for maintaining a waste-free production
environment:
Standardization
Visual controls
Auditory controls
5Wand1HSheet
5.1.1 Standardization
A standard operating procedure is a set of written instructions that describes the step-by-step
process that must be taken to properly perform a routine activity.
While you can write your standard operating procedures according to your organizational needs,
a conventional SOP follows one of the following methods:
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• Checklists. • Ensure the safety of employees.
• Step-by-Step List. • Ensures compliance standards are
• Hierarchical Lists. met.
• Process Flowchart. • Improved communication.
• Time-saving.
5.3 Preventing wastes/MUDA visual and auditory control methods
The factory is a living thing and must constantly be adjusted to stay responsive to changes in the
environment. Responsiveness must be systematic so that problems are addressed without losing
the solid foundation of the waste-removing methods already established. The best way to do this
is through visual and auditory controls.
Red-tagging – You probably did this at the beginning of your improvement activities when you
implemented 5S. If not, do it now: put a red tag on everything in the factory that is not necessary
to the current operations of the production process. After everyone has had time to notice red-
tagged items and claim any that are needed in their area, remove the remaining red-tagged items
from the environment.
Management can decide what to do with them: they can be sold, thrown out, or moved to a location
where they are needed. Always keep the production floor free of any thing that is not directly part
of the production process.
Signboards- The purpose of workstations and the names of the workers who operate them should
be displayed at every processing point. Signboards can also identify equipment and processes so
that everyone knows what things are and what they are used for. Standard quantities’ should be
included on supply bins or carts. The products produced on each line or in each cell can be
displayed, and so on.
Outlining- Boarders around tools and equipment, big and small, help people find and return
things. Outlining can also create patterns of work-flow by using the floor to indicate where and
where not to place things, where to walk, safety zones and danger zones. Outlining to indicate
goods to be processed or parts that have been processed becomes a signal to material handlers for
replenishing or for delivery to the next process.
Andons- Different colored lights can report the status and needs of a system and signal when
defects or abnormal conditions occur so that problems can be solved immediately.
5.4 Creating waste-free workplace using 5W and 1H sheet
The 5W and 1H Sheet The 5W and 1H (five “whys” and one “how”) is a powerful method and
one that never stops being wasteful in sustaining a waste-free production environment. The 5W
and 1H sheet is a tool that will help you systematically apply this method.
What is the Where does the When does Who is How does it happen?
problem? problem happen? it happen? responsible?
Order slips are At the tables During the The waiters The waiters fill out the
not filled out lunch peak order slips while
correctly welcoming other guests
or acknowledging other
guests' requests for
assistance
Why is it a Why does it Why does it Why is this Why does it happen that
problem? happen there? happen person way?
then? responsible?
The food served This is where the There are so They are the There are not enough
is not what the order-taking is done. many guests. ones taking the waiters during lunch, so
guests ordered. orders from the the waiters try to respond
guests. to the needs of many
customers at the same
time
5W1H Approach (II)
What should be Where should it When should it Who should be How should it be
done? be done? be done? responsible? done?
Why should it be Why should it be Why should it be Why should this Why should it be
done? done there? done then? person be done this way?
Is there a better responsible?
way?
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Five Key Concepts for Asking “Why” and “How”
Following these principles suggested by Hiroyuki Hirano when you are asking the 5”whys” and
1”how”: • look with the eyes of a child- All improvement begins with the first why. Never cease
looking and never cease asking that first why. As you practice this, the result will follow.
Remember three essentials for fact finding- (1) Go to where the problem occurred.(2) See the
problem first-hand. (3) Confirm the facts based on your own observations.
Be a walker and an observer- Supervisors and managers must continually work through the factory
to see that standards are being followed and to practice seeing waste. Operators need to continually
examine their own operations to stay alert for new problems and new ideas for solving them that
may come to mind as they do their jobs.
Break down fixed thinking- If you ask “why” and “how” often enough you will eventually run
out of “known” answers. At this point you may reach internal mental resistance to the discovery
of what you don‟t know. Get in the habit of asking why and how beyond this point of fixed
thinking. That is when you will make the big discoveries about waste and how to solve it.
Standard operating procedure is a set of written instructions that describes the step-by-step process
that must be taken to properly perform a routine activity.
Step 1 – Develop a list of processes that you believe need SOP creation
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Self-check 5
Directions: Answer all the questions listed below. Use the Answer sheet provided in the next
page:
1. What are the four methods for maintaining a waste free production environment?
2. How standardization does maintains a waste free environment?
3. How 5W and 1H sheet does maintains a waste free environment?
4. Write at least two methods how to eliminate each of the seven deadly wastes.
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Operation Sheet 2
Planning and procedures for elimination of Muda.
1. The documents of the already identified wastes in several processes or work areas are analyzed.
2. Rank the improvements that are needed. Focus on improvements on the process with the
greatest total when you add up the magnitude of its wastes.
a. Using the more detailed waste-finding checklists provided, find more specific instances of
waste.
4. Set target
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Lap test 5
Practical demonstration
Instructions: Given necessary templates, tools and materials you are required to perform the
following tasks within 1 hour.
Task 1: Choose the first process to be improved, set target and prepare action plan.
Task 2: Set countermeasure to eliminate/reduce the wastes, implement them and check the result.
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Reference
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Author/Copyright September, 2022
Participants of this Module (training material) preparation
4 Sisay Dawit MSc. A-Level Automotive Technology Harar PTC 0910672115 [email protected]
5 Yohannes Negatie MSc. A-Level Automotive Technology W/ro Siheen 0922094453 Yohannes2013n@ gmail.com
PTC