Lean and CI poster
Updated · Free to print and share
8 wastes of lean poster (DOWNTIME)
The 8 wastes of lean are the kinds of activity that use time and resources without adding value for the customer: defects, overproduction, waiting, non-utilized talent, transportation, inventory, motion and extra processing, remembered as DOWNTIME. Taiichi Ohno described seven; unused talent was added later. This poster gives each waste a definition and an example, plus mura (unevenness) and muri (overburden), which cause much of the waste.
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The words on the poster
The 8 wastes: DOWNTIME
Waste is anything the customer wouldn't pay for. Learn to see it.
- Defects Scrap, rework, errors. A rework bench.
- Overproduction More, or sooner, than needed. Big batches.
- Waiting People or parts idle. Waiting for sign-off.
- Non-utilized talent Ideas nobody asked for. Skills unused.
- Transportation Moving things more than needed. Forklift trips.
- Inventory More than the next step needs. WIP piles.
- Motion Walking, reaching, searching. Fetching tools.
- Extra processing More than the customer needs. Double entry.
- Muda Waste
- Mura Unevenness
- Muri Overburden
On the floor
How to use it
- 1
Take it on a waste walk, or put it where the team meets, so everyone uses the same words.
- 2
Mark the wastes you find in your own area with sticky notes on the poster.
- 3
Teach it with the free 8 wastes training deck.
- 4
Pair it with the free waste walk checklist.
Which size to print
- 24 x 36 in or A2: a main wall or team board, read from a few metres away.
- 18 x 24 in or A3: a station or notice board. The A3 file also fits 11 x 17 in paper.
- Letter or A4: a clipboard, binder or handout, on any office printer.
Every PDF is vector, so it stays sharp at full size. Nothing runs to the edge of the page, so no bleed is needed.
Sources and notes
- Taiichi Ohno described seven wastes in the Toyota Production System; non-utilized talent was added later by lean practitioners.
Templates, decks and guides to go with it
- 8 wastes of lean training presentationFree training deck: Value vs waste, the 8 wastes (TIMWOODS) with examples, muda, mura and muri and a waste walk, in 17 slides.
- Waste walk checklist (TIMWOODS)32 things to look for across the eight wastes, with where and how much, and a findings log with dot votes, owners and dates.
- Spaghetti diagram templateSquared paper to trace every trip, a tally of trips and distance, and a before and after comparison.
- Lead time worksheetProduction lead time from the inventory waiting at each step, value-added time and process cycle efficiency, plus an order traced from order to delivery.
- Topic: Lean manufacturing fundamentalsEvery guide we have on the subject, sorted.
- Topic: Value stream mapping and flowEvery guide we have on the subject, sorted.
A poster reminds. A routine makes it stick.
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