FITT Facts: Waste #6

Waste #6 – Over Processing

Have you ever tried to crack open a walnut with a sledgehammer?  How about carve a turkey with a chainsaw?  If you do these things, as silly as they sound, you will get the result you’re looking for (opening the nut or carving the turkey) but you won’t achieve a quality product and will generate a lot of waste in the process. 

Over processing is defined as using ineffective processes, systems, tools or procedures to achieve a quality product or service.  Try to think about any areas where you’re putting too much effort into completing a task or process.

Over Processing Examples	What to do about it…
Using a wrench to tighten bolts and fasten tooling.	Next best practice would be to use a ratchet, even better would be to use an air ratchet/gun, and the ultimate is to use a quick connect.
Having a back and forth e-mail conversation.	Pick up the phone.  Better yet, if that person is in your office then go talk to them.
Creating long and/or arduous forms (maybe in triplicate…)	Simplify the form.  Ask why the form and its parts are needed.  Was it created due to an exception?  Processes should be designed to handle the normal scenario (as waste-free a possible) and people should be allowed/trained handle the exceptions.  Processes that are created to deal with exceptions end up creating a lot of red tape.

When your inner lean champion says something like “there’s got to be a better/easier way…” Listen.

Be FITT!