Identifying Mura-Muri-Muda in the Manufacturing Stream: Toyota Production System Concepts
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About this ebook
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.
Mohammed Hamed Ahmed Soliman
Dr. Mohammed Hamed Ahmed Soliman is an internationally recognized Lean expert, author, and university lecturer. He has published over 100 books and articles on Lean thinking, quality systems, and industrial excellence. He currently teaches Industrial Engineering and Management Systems at the American University in Cairo, an Executive Advisor and a member of the Advisory Committee of the IEOM International Society, and consults for global organizations across manufacturing, public services, and education. With nearly two decades of academic and professional experience, Dr. Soliman has trained professionals across the Middle East, including engagements with Princess Nourah University in Saudi Arabia and Vale Oman Pelletizing Company. He has designed and delivered over 60 leadership and technical development programs, helping organizations build a culture of continuous improvement and operational excellence. Earlier in his career, he worked in various industrial sectors including crystal-glass manufacturing, fertilizers, and chemicals, while educating teams on the Toyota Production System. He has led numerous lean transformation projects, delivering measurable results and uncovering substantial cost savings by targeting waste across production and service environments. His lectures and training materials have reached over 200,000 learners via SlideShare, and his research is ranked among the most downloaded papers on the Social Science Research Network (SSRN) by Elsevier. Dr. Soliman holds a BSc in Engineering, a master's in Quality Management, and postgraduate degrees in Industrial Engineering and Engineering Management. He also holds certifications in quality, cost, and operations management. He is a member of the Institute of Industrial and Systems Engineers (IISE) and the Society for Engineering and Management Systems (SEMS). His insights have been featured in SAGE Publications, Industrial Management, Lean Thinking, and other peer-reviewed platforms.
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Identifying Mura-Muri-Muda in the Manufacturing Stream - Mohammed Hamed Ahmed Soliman
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