Overprocessing Waste

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  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.

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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.

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Challenge:

• What types of overprocessing do you see on a daily basis?  Share your thoughts in the comments section below and receive a coupon to one of Lean Strategies International LLC's courses.

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