A German production director listed 151 types of waste in Chinese factories – it’s shocking to read!

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An production director at Adler Mercedes, he has been serving three Chinese companies since 2008. Currently, he is helping these Chinese enterprises implement Industry 4.0 technologies. Over the past five years, Adler has identified a staggering 151 types of waste occurring in Chinese factories... http://p3.pstatp.com/large/pgc-image/9a7bf4c25200408bae48a3184ad1a56d In Adler’s management notes, we find densely written yet neatly organized entries; Mr. Adler further categorized these 151 types of waste into eight categories:

1. **Waste of time**: Lack of proper planning leads to employees waiting during specification changes or idling due to lack of materials. Supervisors fail to fully understand orders and instructions given to them. There is also a lack of awareness regarding daily work tasks. Employees are unclear about supervisors’ directives. Tools, materials, and small devices are not kept in designated places. Overtime occurs even when it shouldn’t. It is also common for workers to be assigned unsuitable tools or equipment. Some employees deliberately avoid tasks they’re capable of performing. There may be a shortage of needed personnel, while at the same time too many redundant staff remain employed. Poor reporting skills and inability to fill out forms correctly are also issues. Employees develop bad habits such as chatting, leaving their posts without permission, and wasting time. Supervisors neglect to investigate or correct reasons behind employees’ absences or unexcused leaves. They fail to ensure punctuality among workers and are lax in supervision. Decision-making is delayed. Supervisors themselves frequently take unnecessary leave, arrive late, or fail to adhere to schedules. Reports are submitted late. When repairs are required, causes aren’t promptly investigated. Unnecessary conversations and inquiries also occur during work. Finally, supervisors struggle to properly organize their own workload and time.

2. **Waste of creativity**: Management fails to listen to employees’ suggestions or encourages them to offer more ideas. Opinions from subordinates on various matters are not solicited. There’s a lack of thorough research into methods related to one’s own job and business. New hires’ prior work experiences aren’t asked about to gain useful insights. Managers don’t consult other departments (e.g., engineering) adequately. No suitable personnel are assigned to handle valuable proposals. Valuable insights gained from meetings are ignored. Overall, management capabilities are poor.

3. **Waste of materials and supplies**: Poor supervision results in material wastage. Insufficient guidance is provided to new workers. Instructions for new tasks are inadequate. Blueprints or sketches may be damaged, hard to comprehend, or contain errors; standards might not be updated timely, or assumptions may be made by staff. Machinery malfunctions or isn’t properly adjusted. Material usage per process isn’t monitored (standard vs. actual analysis). Subordinates aren’t educated on the value of materials/supplies. Orders and instructions remain vague. Improper handling of materials is tolerated. Employee eyesight and health are neglected, leading to defective products. Discipline is lacking; carelessness or improper work practices are permitted. Workers are allowed to use unsuitable materials—either overly good or inferior ones. Responsibility for defective work isn’t traced back to specific individuals, making corrections impossible. Staffing assignments aren’t based on suitability, especially for newcomers. Excessive materials are requested, yet returns aren’t processed for surplus items. Incorrect materials are ordered and used. Proper arrangement and placement of materials aren’t checked. Leaks or damage in pipes and wiring carrying steam, water, gas, electricity, or compressed air go unnoticed. Employees are permitted to use oil, compressed air, tools, chemicals, etc., for personal purposes. Defective materials are mistakenly passed on as acceptable ones into production. No effective system exists to prevent material loss, theft, or leakage. Reusable materials are treated as waste. Wasteful or abusive use of supplies like brooms, stationery, oilcloth, light bulbs, and pipes is tolerated. Production continues despite the presence of defects.

4. **Waste of machines and equipment**: Absence of work plans means available machinery isn’t utilized optimally. Machines aren’t regularly inspected to maintain good condition and prevent breakdowns. Supervisors lack knowledge on correct machine operation and don’t understand each machine’s capabilities. Regular checks of ropes, belts, chains, conveyor belts, lubrication systems, etc., are neglected. Large machinery is used for minor tasks. Coordination with maintenance departments during upkeep, repairs, and painting is lacking. Idle machines aren’t maintained; they succumb to moisture, dirt, dust, and rust. Regular cleaning doesn’t occur, leaving machines filthy. Moving parts aren’t checked for adequate lubrication. Repairs aren’t carried out promptly. Appropriate operating manuals are absent. Discipline is weak, allowing misuse of equipment. Employees are permitted to repair machines using “improper methods.” Supervisors aren’t aware of latest machine models. They fail to emphasize the importance and condition of machinery to subordinates. Small machines are misused for heavy-duty tasks. Machines that should be scrapped are repaired at greater cost than buying new ones; conversely, repairable machines get discarded. No efficiency metrics (machine efficiency) are tracked.

5. **Waste of manpower**:
1. Personnel turnover among competent staff can’t be controlled due to: failure to assess direct/indirect costs of staff changes; excessive micromanagement coupled with few truly skilled leaders; overly strict or lenient discipline enforcement; broken promises (e.g., raises/promotions); unjustified dismissals used punitively; forcing staff into jobs they dislike; unfair treatment; favoring one employee over others during disputes; indirect criticism of staff members; failure to identify reasons behind voluntary resignations; inability to convey company goals/policies clearly; supervisors excluded from salary adjustment decisions; weak supervisory authority.
2. New hires fail to reach full productivity because: they aren’t warmly welcomed or given safety training; they aren’t informed about daily duties; unqualified personnel are hired; patience isn’t shown toward slower learners; existing staff don’t foster friendliness toward newcomers; insufficient effort is made to bond with new workers; crucial factory information (safety rules, pay dates, restroom locations, drinking water, showers) isn’t shared; no comprehensive training program exists.
3. Subordinates don’t perform to their potential because: they receive no guidance on how to excel; work isn’t explained engagingly enough to spark interest; supervisors ignore progress and personal lives; tolerance for mistakes is low; assignments don’t match individual strengths/personalities; diversity among staff isn’t leveraged; cliques form; evaluations focus solely on qualifications, race, religion, connections, or region; unsuitable individuals aren’t reassigned despite known limitations; sick employees still work; necessary support is denied; promotions are delayed when warranted; salary/work conditions aren’t optimized; no backup candidates are trained.
4. Lack of understanding regarding standard working hours.
5. Absence of data tracking workforce efficiency.

6. **Waste caused by accidents**: Prevention of accidents isn’t recognized as part of job responsibilities. Safety procedures aren’t thoroughly communicated to all staff. Safety guards on machinery aren’t installed or maintained effectively. Misuse of safety gear is tolerated. Hazard signs aren’t posted clearly, and areas stay dirty/unreadable. Indirect costs of accidents remain unappreciated. Materials aren’t stored properly. Underlying causes of hazards aren’t understood. Accident records aren’t maintained, analyzed, or applied practically. Positive safety examples aren’t established. Inspections aren’t regular or thorough. Safety rules aren’t consistently enforced. Workers lack essential protective gear (gloves, harnesses, welding masks). Managers overlook their safety responsibilities and liability. Employee safety awareness isn’t cultivated or sustained. Cooperation with external safety inspectors is lacking.

7. **Waste due to poor cooperation**: Collaboration with other managers/departments is nonexistent. Company policies aren’t fully grasped or explained to staff. Rumors aren’t handled intelligently. Blame gets shifted onto other supervisors, subordinates, or superiors. Employee feedback isn’t relayed appropriately to leadership. Dissenting employees are allowed to incite resistance against the firm. Managers don’t wholeheartedly promote less-established company rules. A spirit of camaraderie/cooperation among staff isn’t nurtured. Within their own units, managers casually criticize company policies/personal conduct. Genuine collaboration with upper management on educational initiatives (apprenticeships, bulletin boards, newsletters, suggestion schemes) is absent.

8. **Waste of space**: Poor organization and tidiness. Materials aren’t stored or disposed of properly. Factory logistics planning is neglected. Permanent machinery/equipment placement is illogical. Subordinates leave hand tools, ladders, carts, etc., in walkways, obstructing cleanliness. Scrap materials aren’t disposed of properly. Cabinets, oil drums, supply closets are situated inconveniently. Unused machines/equipment occupy valuable space. Needed space remains unused due to delayed repairs (floors, roofs). Lighting deficiencies create dark zones/blind spots. Layout within units lacks order. Unnecessary items clutter workspaces; warehouses/factories aren’t clearly separated. Importance of organization isn’t appreciated. Employees aren’t taught to return items to their proper places after use. Periodic cleanup routines (daily/weekly/monthly) aren’t rigorously implemented to sustain order