Waste of Overproduction, 7 Wastes in Lean Manufacturing (SIX Sigma)

Overproduction occurs if more products are manufactured than it was planned by the production plan, or if products are manufactured faster that it was planned. Consequences are piles of too early deposited products in intermediate warehouses. In order to prevent that a worker on a machine in a production line would not be without work, he starts processing the next operational order immediately after having finished the previous one. This new product was planned to be manufactured later, so the worker creates overproduction, which requires intermediate warehouses. The company should have a good overview of overproduction, so it has to organize the work in such a way the overproduction is clearly visible.
Overproduction can be eliminated by informing and convincing the workers that they have to stop working the moment when the daily production plan has been achieved. It is better that workers do not work than that they do something that they do not need.

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Muhammad Mubashir Ghori

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