Sort the Waste You Can Actually See

Sort each shop-floor observation into the strongest waste category. Defects/Rework Waiting Motion Inventory Overprocessing Operators relabel 80 cartons because the product code printed wrong upstream. A press operator stands idle for six minutes waiting for material handling. The torque wrench is stored 35 feet from the station and used every unit. Three pallets of obsolete revision parts sit beside the current line. Quality checks the same serial number at incoming, assembly, and final with no added decision. Painted housings loop back for touch-up after dust appears under the finish. A completed batch waits overnight for a full rack before final…

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