Lean Principles and Waste Elimination
7
Wastes
TIMWOOD or DOWNTIME depending on the memory aid
Pull
System
Work is pulled when capacity exists
5S
Workplace
Sort, Set, Shine, Standardize, Sustain
every process leaks · spot the seven, plug the worst
The 7 Wastes · TIMWOOD
Transport
→→→
Moving files, parts, or people between steps that shouldn't need movement.
Inventory
▦▦▦
Stockpiles of unfinished work, untested code, undeployed releases.
Motion
↻
People walking, reaching, clicking through layers to do one task.
Waiting
⧗
Person waiting on approval, ticket, build, review, next shift.
Overproduction
∞
Building more than the customer asked for. Worst waste of all.
worstOver-processing
✦✦
Polishing what the customer didn't ask for. Gold plating belongs here.
Defects
✕
Bugs, rework, scrap, wrong shipments. Every defect doubles cost.
how to read this
- › TIMWOOD is the memory hook — one letter per waste.
- › Walk any process with this list and you will find at least three wastes within 10 minutes.
- › Overproduction is the worst — it hides every other waste inside piles of unneeded work.
- › Lean asks: "would the customer pay for this step?" If no, it's waste.
Exam Traps
Defects are waste
Rework is considered a waste under Lean. Preventing defects is cheaper than correcting them.
Overproduction is the worst waste
Building more than the customer needs creates inventory, cost, and hides other problems. Lean hates overproduction above all.
Value stream mapping exposes waste
VSM shows where time is spent, where queues form, and where waste hides. The exam tests awareness of this tool.
Pull, do not push
Work enters the system when there is capacity. Pushing overloads the system.
Waste is everywhere
Seven categories. Learn to spot them in every process.
Making 20 sandwiches when you have 5 customers. Stale bread, wasted money.
The slicer is broken and everyone stands around. Waste of time.
The deli meat is stored in the basement. Every sandwich means a trip downstairs.
A wrong order means a new sandwich. Rework costs double.
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