Kind of Wastes in textile production process

According to David Magee, (Magee, 2007, p. 67) different kinds of wastes in a process can be categorized in following categories. These wastes reduce production efficiency, quality of work as well as increase production lead time.

1.      Overproduction – Producing items more than required at given poin t of time i.e. producing items without actual orders creating the excess of inventories which needs excess staffs, storage area as well as transportation etc.

2.      Waiting – Workers waiting for raw material, the machine or information etc. is known as waiting and is the waste of productive time. The waiting can occur in various ways for example; due to unmatched worker/machine performance, machine breakdowns, lack of work knowledge, stock outs etc.

3.      Unnecessary Transport – Carrying of work in process (WIP) a long distanc e, insufficient transport, moving material from one place to another place is known as the unnecessary transport.

4.      Over processing – Working on a product more than the actual requir ements is termed as over processing. The over processing may be due to improper tools or improper procedures etc. The over processing is the waste of time and machines which does not add any value to the final product.

5.      Excess Raw Material - This includes excess raw material, WIP, or finished goods causing longer lead times, obsolescence, damaged goods, transportation and storage costs, and delay. Also, the extra inventory hides problems such as production imbalances, late deliveries from suppliers, defects, equipment downtime, and long setup times.

6.      Unnecessary Movement – Any wasted motion that the workers have to perform during their work is termed as unnecessary movement. For example movement during searching for tools, shifting WIP etc.

7.      Defects – Defects in the processed parts is termed as wast e. Repairing defective parts or producing defective parts or replacing the parts due to poor quality etc. is the waste of time and effort.

8.      Unused Employee Creativity – Loosing of getting better ideas, improvement, skills and learning opportunities by avoiding the presence of employee is termed as unused employee creativity (Liker, 2003, p. 29).