A training on Muda, Mura & Muri in Lean manufacturing

1. A Training on 3 M’s in
Lean Management
By
Pramod A

2. Dec 2015
Lean Management
• Lean Management of “Lean” is the optimal way of
managing a process through the removal of wastes and
Implementing a flow.
• More value with Less work
• Lean Manufacturing is mostly derived from Toyota
Production System (TPS) and identified as “Lean” only after
1990.
• Ultimate goal is the removal of all wastes in the Process.

3. Dec 2015
Toyota Production System
• Make what the customer needs, when it is needed, and
in right amount.
• Minimize Inventories.
• Full utilization of all Potentials.
• Building Quality in the process and Prevent errors from
happening.
• Reduction of through put time.

4. Dec 2015
Lean Production - TPS
The Main goals of TPS are to eliminate 3 M’s which are,
• Muri (Overburden or stress in the system)
• Mura (Inconsistency, Un-evenness)
• Muda (Waste)
Ultimate Goal is to design a process that runs smoothly, without stress
and eliminates wastes.

5. Dec 2015
3 M’s

6. Dec 2015
Muda
What is Muda?...
• Work that does not add any value to the product
or the activities which the customer is not
paying for.

7. Dec 2015
Economic Value of Muda
• Every Business activities
absorb resources and
each resource has a cost.
• Every waste has a cost
and that is a direct loss to
the company.
• Economic value of the
waste in a process
industry are in the range
of 10% - 35% of annual
turnover

8. Dec 2015
Types of Muda
7 Types of Muda

9. Dec 2015
Muda of Motion
Movement that does not add value.
• Searching of Files
• Gathering Information
• Looking through manuals and
catalogs
• Handling Paperwork
“The Movement of People Within the Workspace”

10. Dec 2015
Muda of Waiting
Waiting constricts smooth flow. it interrupts
the work rhythm
• Job waiting to be loaded into a machine
• Products waiting for inspection
• Waiting for raw materials and parts
• Customer Response

11. Dec 2015
Muda of Transport
• Transportation adds time to the process
without increasing value, and creates an
opportunity for damage to occur.
• Poor plant layout leads to transportation
wastes, and waste can be removed by
achieving the shortest distance in a
straight line.
"The Unnecessary Movement of Materials"
Some results of unnecessary transportation:
• cost
• damage
• time lost
• spillage
• wasted investment in logistic equipment

12. Dec 2015
Muda of Over Production
"Producing More than Required Amount"
Overproduction arises from
fear or concerns of stock outs
or a misunderstanding of
demand
• A process that continues
when its output is not
required causes excess
inventory. Over-production
is generally regarded as the
worst type of waste, it leads
to all the other wastes.
• “Produce the right amount
at the right time.”

13. Dec 2015
Muda of Inventory
Get rid of 'just in case inventory'; it ties
up cash and requires additional storage
facilities. Excess storage can cause
stock damage, and materials can
degrade in store.
• Old stock items that aren’t currently
used in production.
• Needs space.
• Costs money.
• Requires finding.
• Needs intermediate storage and
people to move them.
• can hide problems
"Stock that is Not Required for Customer Orders"

14. Dec 2015
Muda of Over Processing
"Doing More than needed to Meet the Customer Requirement"
Efforts that create no value from
Customers view point
• Completing two or three
inspections,
• Measuring components more than
once
• Use of Outdated standard forms

15. Dec 2015
Muda of Defects
Producing parts, products, or services that are
defective results in scrap and rework; it also
wastes supplies and leads to customer
dissatisfaction.
• Making items to the wrong specification
The production of defects or scrap results in:
• additional materials usage
• additional transportation
• additional control
• space for quarantined stores
• space for repairing
Reduce defects and scrap through:
• Search for and elimination of causes
• Build in Quality (QA process sheets)
"Doing Nice or Do It Twice"

16. Dec 2015
Mura
Eliminating unevenness or irregularities in any
operation or process is one of the main principles of
the Just-In-Time system, the main pillar of the
Toyota Production System.
• Mura is the waste of unevenness or inconsistency.

17. Dec 2015
Muri
Muri is the Over Burden on equipment, Facilities
& People caused by Muda and Muda.
• Pushing a machine or person beyond its limits.

18. Dec 2015
Muri
Results
• Overburdening peoples results in safety and
quality problems.
• Overburdening machines causes breakdown
and defects.

19. Dec 2015
Lean Solutions
• First you must see it – MAKE IT VISIBLE!

20. Dec 2015
Lean Solutions - Value Stream Mapping
You can See and Identify Waste as you connect
your processes from start to finish

21. Dec 2015
Lean Solutions
• Problem Solve
Plan Do
CheckAct

22. Dec 2015
Lean Solutions
• Keep watching