CMA Intermediate · Operations Management and Strategic Management · Lean Operations and JIT
In a Chennai auto-component plant, operators walk 40 metres to fetch a gauge from a distant cabinet several times each shift. Which waste is this, and what is the best lean remedy?
This is motion waste, since operators make unnecessary movements to fetch a gauge. The remedy is to keep tools at the point of use through 5S and workplace layout improvement, which removes walking without adding any value for the customer.
- AMotion waste; place tools at the point of useCorrect
- BTransportation waste; use larger transfer batches
- CWaiting waste; add more operators
- DInventory waste; reduce the cabinet size
Explanation
Unnecessary movement of people within a workstation or while fetching items is motion waste. Ergonomic layout and keeping tools at the point of use (5S) reduce it. Transportation refers to moving materials or products, and larger batches would worsen flow.
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