operations is called “motion” rather than “work.” In everyday
work operations, there is rarely a clear distinction between
actions that actually are “working” and those that merely are
“moving.” The two just mix together in our overall actions.
What seems to be “working” at one instant may turn into
“moving” at another, and vice versa.
It is not easy for an untrained eye to distinguish between
the two. Many factories make the careless mistake of starting
out their improvement campaigns with the general notion
that whatever moves is work and what does not is waste.
Obviously, their improvement campaigns are not going to
be very successful until they learn to make the distinction
between “work” and “motion.”
Waste that is not recognizable as such is the most insidious
kind of waste. If we can learn to recognize this kind of waste,
we are well on our way to success in eradicating waste.
The following is a list of some of the things we might
encounter as we stroll through a typical factory. Odds are
that we would not be able to recognize these motions as
10 examples of waste.
1. Workers grunting and groaning as they carry a heavy load.
2. Workers counting parts once the operation is done.
3. Workers moving stacks of parts from the floor to a cart.
4. Workers inserting parts into plastic bags before sending
them downstream.
5. Workers removing the plastic bags from parts received.
6. Workers who have finished today’s work and are proudly
starting in early on tomorrow’s.
7. Workers securing parts to be processed.
8. Workers repeating the cycle of picking up parts, processing
them, and setting them down elsewhere.
9. Workers watching out for defects while their machines
are operating.
10. Workers searching for parts, tools, or jigs.
Destroying Factory Myths ◾ 77
The above are 10 typical examples of waste in factories. I
could list more. In fact, I could fill this entire book with typical
examples of waste. That is how much waste exists in factories.
Imagine standing with the president of the company that
owns the factory and watching such a waste-filled factory in
operation. What do you suppose the president might say if
you remarked, “Boy, your workers are really moving around
a lot, aren’t they?”
Unfortunately, a large number of company presidents
would respond with something like, “Yeah, our factory people
really work hard for us.”
Personally, I would not blame you if you responded to
that by making a sour bulldog face and stomping out of the
factory. When people fail to recognize the difference between
“motion” and “work,” you can be sure their eyes are blind
to waste. Let us see just how different “motion” and “work”
really are.
The only result of motion is higher costs. Well, actually,
it has one other result: eating up profits. Now you see why
we call “motion” waste. In sharp contrast to this, the result
of “work” is to fulfill a function. This function is generally a
value-adding function.
Motion and work are mixed together within the typical
equipment operator’s activities. But motion (waste) is clearly
the main ingredient. As a result, the equipment operator’s
activities actually add very little value.
Consider the example of a press operator illustrated in
Figure 2.17.
1. The first step in the press operator’s activity: picking up
and moving an unprocessed workpiece.
This movement adds absolutely no value to the workpiece.
Therefore, it is an example of waste. The waste
can be reduced by shortening the distance of this movement.
Of course, the best thing would be to eliminate
the movement (and the waste) altogether.