Eliminate Waste: Overprocessing and Defects

Eliminate poor training, non-standard work procedures, and poor communication to eliminate waste

Sorin Dumitrascu
Apr 4 · 3 min read
Eliminate Waste: Overprocessing and Defects — abstract illustration
Eliminate Waste: Overprocessing and Defects — abstract illustration
Photo by pichetw on depositphotos

More work and rework than necessary

Defects — flaws in a product or service — are inherently wasteful, because they force a product to be discarded or reworked. So where there are defects, there is likely unnecessary rework, which is a form of overprocessing.
If you have waste, you need to find out what caused it.

One method is 5 Whys, or asking “why” five times whenever a problem occurs. For example, why did this customer file a complaint? Because an error appeared the web site. Why was there an error? Because a programmer inserted inaccurate code. Why didn’t someone check it for accuracy? Because that’s not part of the process. And so on.

Root causes of defects and overprocessing

Lack of trust, incorrect equipment or software, misunderstandings, and lack of innovation also contribute to overprocessing.

Defects occur for various reasons — poor processes, variations in a process, or machines that are inaccurately designed or engineered. Insufficient on-the-job training may cause a lack of skills, which can create defects.

Eliminating overprocessing and defects

Poka yoke

Training

Statistical process control

Standard work

Kaizen

Lean strategies help support your organization’s efforts to eliminate overprocessing and defect waste.

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Sorin Dumitrascu

Written by

A consultant, trainer and author specialized in management, corrections and industrial relations

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Sorin Dumitrascu

Written by

A consultant, trainer and author specialized in management, corrections and industrial relations

Loud Updates

Join Loud Updates and we help you to make your word loud

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