Sort waste by the lean loss it creates

Sort each plant observation into the waste bucket it best represents. Defects or rework Waiting Motion or transportation Inventory or overproduction Extra processing or unused talent Operators walk 38 steps to retrieve a shared go/no-go gauge Finished pallets wait two hours for a forklift move to staging The press runs extra parts because changeover is painful A label defect forces the team to open and relabel sealed cartons Operators enter the same lot number into two unconnected systems Maintenance apprentices see a recurring failure pattern but are not asked during review Material handlers move WIP to temporary space and back…

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