Waste of Over-Processing , 7 Wastes in Lean Manufacturing (SIX Sigma)

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The waste of Over-processing is where we use inappropriate techniques, oversize equipment, working to tolerances that are too tight, perform processes that are not required by the customer and so forth. All of these things cost us time and money.

One of the biggest examples of over-processing in most companies is that of the “mega machine” that can do an operation faster than any other, but every process flow has to be routed through it causing scheduling complications, delays and so forth. In lean; small is beautiful, use small appropriate machines where they are needed in the flow, not break the flow to route through a highly expensive monstrosity that the accountants insist is kept busy!

Waste of inappropriate processing is a consequence of a poorly planned production process of the product. The product does not satisfy requirements and has to be reworked; sometimes it is even useless. The reasons for waste of inappropriate processing can be found by using the fishbone diagram. Waste of inappropriate processing can be eliminated by a thorough analysis and continuous improvement of manufacturing process. 

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