1. Muda (Waste)
Muda refers to activities that do not add value from the customer's perspective.
Transport: Unnecessary movement of products or materials.
Example: Moving parts back and forth unnecessarily.
Inventory: Excess products or materials not being processed.
Example: Overstocking raw materials.
Motion: Unnecessary movement of people.
Example: Workers walking long distances for tools.
Waiting: Idle time waiting for the next process step.
Example: Machine operator waiting for parts.
Overproduction: Producing more than needed.
Example: Manufacturing more units than orders received.
Overprocessing: Doing more work than necessary.
Example: Using higher precision equipment than required.
Defects: Efforts to inspect and fix errors.
Example: Reworking products due to quality issues.
2. Mura (Variability)
Mura refers to inconsistencies in operations, leading to waste.
Example in Production: One process finishes faster than the next, causing work-in-progress inventory.
Example in Service: Call center with fluctuating call volumes, leading to overstaffing and understaffing.
3. Muri (Overburden)
Muri refers to overburdening workers or machines, causing stress, mistakes, and breakdowns.
Example in Production: Workers operating at maximum capacity without breaks, leading to burnout and errors.
Example in Equipment: Machines running continuously without maintenance, leading to breakdowns.
Real-World Example: Automotive Assembly Line
Muda: Unnecessary transport of parts and excess inventory.
Mura: Workstations completing tasks at different speeds, causing bottlenecks.
Muri: Workers performing at maximum speed without rest, and machines running continuously without maintenance.
