The easiest way to define overprocessing is doing more to a product than what the customer, specification or transformative process requires the first time through.  Overprocessing is sometimes referred to as inappropriate processing because it includes steps that are not needed, extra handling, duplication of activities and processes that are just not statistically capable of producing the desired results.

Examples:

1. Using multiple software systems.
2. Pulling data from multiple reports.
3. Using screws and fasteners where clamps could be used.
4. Using the wrong tools for the job.
5. Performing the same process step multiple times.

Solutions:

• Review the value stream of the process or product flow.
• Drill into each process step using the 5 why's to determine if it is really needed.
• Remove duplicate work activities and excessive check points.

Question:

  What types of overprocessing do you see on a daily basis?

**Place answers in comments tab below.**

  Overproduction is one of the 8 major forms of waste.  It occurs when parts, services or information are created in excess of the needed demand or when services, products or information are created/delivered in advance of the needed schedule.  To learn more about Overproduction click on the link below and enroll in our 8 forms of waste course.

Topics for discussion:

  Overproduction is considered to be the deadliest waste of all forms of waste.  Why in your opinion is this form of waste so "deadly?"

  A backlog is every customer order that has been received as an order that has not yet fulfilled the customers request.

  Transportation waste is any unnecessary movement of people, products, materials or information.

Examples:

1. Moving parts across facilities.
2. Walk excessive distances to retrieve tools.
3. Retrieving or storing, information, files and data.

Caused by:

1. Functional or widespread equipment, poor layout.
2. Minnimal cross-training of work centers.
3. Queue points in and out of operations. 
4. Tools not prioritized by usage and located close to the point of use.
5. Information located in "storage" centers.

  The waste of motion or movement is any motion or movement by people and or machines that does not add or create value.


Examples:

1. Excessive movement.
2. Reaching to high or to low.
3. Excessive clicking or key strokes on a computer.
4. Looking for tools.
5. Email attachments and CC's of unnecessary people.

Caused by:

• Poor work or office layouts.
• functional or widely spaced equipment.
• Inconsistent work methods.
• Poorly designed ergonomics.

Solutions:

1. Standardize work activities.
2. When setting up offices or machine layouts include the people who work in the area.
3. Use automation where possible.

Question:
  What types of motion waste do you observe from day to day?

**place answers in comments section**

  Inventory waste is any unnecessary storage of materials, products or information.


Examples:

1. Excessive raw materials.
2. Unsold finished goods.
3. Excessive amounts of MRO items.
4. Information and data that is being stored but not used.
5. Excess supplies, including office supplies.
6. Emails sitting in inbox.

Causes of excess inventory:

1. Working to a push system or a forecast.
2. Unbalanced workloads.
3. Buying to many of items.
4. Batching
5. Inefficient or poor planning and scheduling.

Solutions:

1. Build only to demand where possible.
2. Stabilize processes and use six sigma techniques to minimize variability.
3. Remove waste from processes so that inventory (raw,wip,fg,mro) can be reduced.

Question:

  What types of Inventory do you notice at home, work or other places?  How do you think that inventory affects the organization?

​**Place answers in Comments** 

  This type of work activity does not meet the criteria of value added work, mainly because a customer is not willing to pay for the product, service, activity or information.  However, the product, service, activity or information although not considered value added is necessary to either protect the company or comply with regulatory requirements. Because of this it must be performed by the organization.  This type of work is still considered wasteful.

Tip:
  Although business necessary work can not always be eliminated right away these activities should still be reduced or minimized as much as possible until they can be removed.

  Though the spelling of the word “team” does not include an I, the definition does acknowledge that each individual must do their part.  The word team is defined simply as: a group of individuals who come together for a common purpose or to reach a specific objective.​