Identifying Mura-Muri-Muda in the Manufacturing Stream: Toyota Production System Concepts

By Mohammed Hamed Ahmed Soliman

To save money during the economic downturn, many businesses are using abstinence policies. This might mean firing employees and reducing pay for some people. Actually, those actions might only work for a little while. If the company doesn't make a culture of always getting better and change how it works, the problem might happen again and get even worse. This takes us back to the reason why the Toyota production system was created.

Waste means something that takes up resources, but doesn't give anything back to the customer. Many activities are not useful and can be divided into two categories. Even though type one muda doesn't bring any benefit, we can't avoid it because of the resources and technology we have now. An example of this would be inspecting welds to make sure they are safe. We also refer to this as a necessary task that does not add value. Using two unnecessary steps does not make things better and can be easily taken out. An illustration is a way to make a process in a village organized and efficient. It turns it into a cell where things that are not needed can be removed and there is no need for extra supplies. Only a tiny fraction of the activities carried out in a value-stream actually create value that the client truly finds valuable. The best way to improve how well a business does is to stop doing all the things that aren't needed.

• Language: English
• Publisher: personal-lean.org
• Release date: Oct 28, 2023
• ISBN: 9798215193327

Mohammed Hamed Ahmed Soliman

Mohammed Hamed Ahmed Soliman is an industrial engineer, consultant, university lecturer, operational excellence leader, and author. He works as a lecturer at the American University in Cairo and as a consultant for several international industrial organizations. Soliman earned a Bachelor's of science in Engineering and a Master's degree in Quality Management. He earned post-graduate degrees in Industrial Engineering and Engineering Management. He holds numerous certificates in management, industry, quality, and cost engineering. For most of his career, Soliman worked as a regular employee for various industrial sectors. This included crystal-glass making, fertilizers, and chemicals. He did this while educating people about the culture of continuous improvement. Soliman has more than 15 years of experience and proven track record of achieving high levels of operational excellence to a broad range of business operations including manufacturing, service and healthcare. He has led several improvement projects within leading organizations and defined a lot of savings in the manufacturing wastes stream. Soliman has lectured at Princess Noura University and trained the maintenance team in Vale Oman Pelletizing Company. He has been lecturing at The American University in Cairo for 8 years and has designed and delivered 40 leadership and technical skills enhancement training modules. In the past 4 years, Soliman's lectures have been popular and attracted a large audience of over 200,000 people according to SlideShare's analysis.. His research is one of the most downloaded works on the Social Science Research Network, which is run by ELSEVIER. His research is one of the most downloaded works on the Social Science Research Network, which is run by ELSEVIER. Soliman is a senior member at the Institute of Industrial and Systems Engineers and a member with the Society for Engineering and Management Systems. He has published more than 60 publications including articles in peer reviewed academic journals and international magazines. His writings on lean manufacturing, leadership, productivity, and business appear in Industrial Engineers, Lean Thinking, Industrial Management, and Sage Publications. Soliman's blog is www.personal-lean.org.

Book preview

Identifying Mura-Muri-Muda in the Manufacturing Stream

Toyota Production System Concepts

Mohammed Hamed Ahmed Soliman

Published by personal-lean.org, 2023.

While every precaution has been taken in the preparation of this book, the publisher assumes no responsibility for errors or omissions, or for damages resulting from the use of the information contained herein.

IDENTIFYING MURA-MURI-MUDA IN THE MANUFACTURING STREAM

First edition. October 28, 2023.

Copyright © 2023 Mohammed Hamed Ahmed Soliman.

ISBN: 979-8215193327

Written by Mohammed Hamed Ahmed Soliman.

Toyota Production System Concepts

Identifying Mura-Muri-Muda in the Manufacturing Stream

Copyright © 2023

Mohammed Soliman

All rights reserved

Contents

The Beginning

Toyota Production System Lean Basics and Values

1. Value

2. The value stream

3. Flow

4. Don't force production (push)

5. Try your best to be perfect

What is Muda or Seven Wastes?

Connection between Waste and Profitability

"What is Muda, Mura and Muri?

Muda

Transportation

Inventory or Stock Holding

Motion or Physical Movement:

Waiting or Queuing

Overproduction

Over Processing or Duplication

Defects or Faults

Untapped Human Potential or Waste of Talent:

Mura

Muri

The Beginning

Getting rid of waste makes a business more profitable. Processes are grouped into two categories: those that add value and those that do not. The seven deadly wastes that can be found in any manufacturing process started in Japan and are explained in the Toyota production system (TPS). The most important aim became getting rid of them. For every piece of garbage, there is a way to get rid