First Muda - Over Production

Over Production is  First Muda to attack - Why?

Purpose of Lean Manufacturing is to implement a PULL flow in a manufacturing or service flow.But presence of this Over Production is indication of PUSH flow in the plant.It is totally against the objective of Lean manufacturing.We can't step into Lean in a Plant without eliminate this Muda.The activities to eliminate remaining other 6 Mudas without attack this Over Production are also Mudas.

How did Over Production created in a Plant?

a) By poor customer demand forecasting.
b) By failure of customer demand deployment from start to end processes or work stations and keep production schedule against the customer demand is only for end process or last work station.
c) Lack of knowledge in planning to convert a Customer demand into Production Schedule.
d) Concentrating on daily production quantity without concentrating on daily throughput.This is due to playing Number Game without knowing the purpose of Number Game.

What are the indications in our Business to understand that we have over production?

a) We have inventory every where in our plant in various stages(RM,finished and semi finished stage)but our daily dispatches to customer is in premium freight mode.
b) Lower cycle time machine than bottle neck m/c is utilized better than bottle neck m/c.

OK,now we can look into Customer demand Management in next lesson to over come this Over Production..