A German production director identified 151 types of waste in Chinese factories over a period of five years

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A production director of Adela Mercedes-Benz Company, he has provided services to three Chinese companies since 2008 and is now helping Chinese companies promote Industry 4.0 technology. In the past five years, Adela has recorded that there are as many as 151 types of waste in Chinese factories... (Reposted from: Baidu Library) We found dense but neat notes in Edela's management notes, and Mr. Edela also classified these 151 kinds of waste into eight categories... 1. Waste of time 1. Lack of proper planning, causing personnel to wait when changing specifications, or stopping work for materials 2. The squad leader failed to fully understand the orders and instructions he received 3. Lack of understanding of the content of the whole day's work 4. Orders or instructions to the squad leader Unclear 5. Failure to accurately supervise that tools, materials, small devices, etc. should be placed in certain places 6. Work that should not be done overtime, resulting in overtime 7. Failure to check whether appropriate tools and equipment are provided for each job 8. Allowing employees to deliberately avoid the work they can do 9. Insufficient required personnel 10. Keeping too many redundant staff 11. Clumsy in filling out reports and various application forms 12. Indulging employees in the habit of chatting, leaving work without permission, and wasting time * Habits 13. Neglect to inquire and correct the reasons for employees’ temporary absences and leave requests 14. Failure to require employees to start work on time and lax supervision 15. Delay in decision-making 16. The monitor himself unnecessary requests for leave and is late or unpunctual 17. Late submission of reports 18. Failure to check the original source immediately when repairs are needed Reasons 19. Unnecessary conversations and inquiries at work 20. The monitor cannot arrange his work and time appropriately 2. Waste of creativity 1. Failure to listen to employees’ suggestions 2. Failure to encourage employees to make more suggestions 3. Failure to listen to subordinates’ opinions on various issues 4. Failure to conduct extensive research 5. Failure to ask new employees about their past work experience to obtain useful opinions 6. Failure to fully consult other departments (such as biotechnology, etc.) 7. Failure to consider or designate appropriate personnel to handle all useful proposals 8. Failure to obtain useful insights from the meeting Opinion 9. Poor management function 3. Waste of materials and supplies 1. Poor supervision, resulting in waste of materials 2. Insufficient guidance to new employees 3. Insufficient guidance when assigning new work 4. Blueprints or sketches are damaged, difficult to understand, misunderstood, standards are not corrected in time, or self-initiated 5. Mechanical accidents 6. Failure to check the use of materials in each process (standard and difference analysis) 7. Failure to let subordinates understand the value of materials or supplies 8. Unclear orders and instructions 9. Condoning poor material handling 10. Failure to pay attention to the eyesight and health of subordinates, resulting in defective products 11 . Lack of discipline and condoning careless or improper work 12. Allowing subordinates to use inappropriate materials, such as too good or too poor 13. Failure to track the origin of bad work, so that it cannot be corrected 14. Inability to apply appropriate materials, especially for newcomers 15. Requesting too many materials, but not returning excess materials 16. Failure to request the correct materials and using the wrong materials 17. Failure to check whether the materials are arranged neatly and correctly placed 18. Failure to check for cracks and damage in pipes and wires such as steam, water, gas, electricity and compressed air 19. Allowing subordinates to use oil, compressed air, small tools, chemicals for private purposes Medicines, etc. 20. Let defective materials flow into the process as good products 21. Lack of effective systems to prevent materials from flowing out, loss or theft 22. Dispose of reusable materials as waste 23. Connivance to waste or abuse the following supplies: brooms, stationery, tarpaulins, light bulbs, water pipes, etc. to produce defective products Stop production immediately 4. Waste of machines and equipment 1. Lack of work planning, so that all available machines are not fully and appropriately utilized 2. Neglect to check machines to keep them in good condition and avoid failures 3. The squad leader lacks the knowledge to use machines correctly and does not understand the functions of various machines Ability 4. Failure to regularly inspect - ropes, belts, chains, conveyor belts, lubrication systems, etc. 5. Using a machete to kill chickens and using large machinery for small jobs 6. Lack of coordination with the maintenance department in maintenance, repair, and painting work 7. Idle machines are not maintained and are allowed to be corroded by moisture, dirt, dust, rust, etc. 8. Lack of regular cleaning, the machine is unclean. 9. All rotating parts are not checked for proper lubrication. 10. Repairs that should be repaired are not done immediately. 11. The machine does not have appropriate operating instructions. 12. Lack of good discipline to avoid the abuse of machinery and equipment. 13. Condolence to subordinates for improper use. Method "Repair the machine 14. The foreman does not know the latest models of machines and equipment 15. Failure to prompt subordinates to pay attention to the value and condition of the machine 16. Misuse of small machines for heavy work 17. Machines that should be scrapped are still repaired, which costs more than buying new ones 18. Machines that can be repaired are not Report 19. Data without efficient management (mechanical efficiency) 5. Waste of manpower 1. Unable to control personnel changes of capable subordinates due to the following reasons (1) Failure to assess the direct and indirect costs of employee changes (2) Too much "management" and too few smart leaders (3) Discipline Legal requirements are "too strict" or "too loose" (4) "promises" that can be fulfilled but not kept (5) "promises" that cannot be kept, such as salary increases or promotions (6) firing people without good reasons, dismissal should not be used as a punishment (7) forcing subordinates to work in jobs that they dislike extremely (8) criticizing one subordinate to other subordinates (referring to Sang Shuhuai) (9) failing to find out the reason why the subordinate resigned voluntarily (10) failing to correctly explain the company's goals and policies to subordinates (11) the squad leader did not participate in employee salary adjustments (12) the squad leader's authority is not good 2. Can't To enable new employees to give full play to their productivity (1) Failure to accept new employees in a friendly and helpful manner (2) Failure to provide safe work guidance to new employees (3) Failure to let new employees understand the full-day work and other contents (4) Failure to select qualified people to work with (5) Failure to learn * Slow people have no patience (6) Failure to encourage other subordinates to show friendly and helpful attitudes to newcomers (7) Failure to get as close to newcomers as possible (8) Failure to inform newcomers of factory life conditions and plans, such as safety, pay dates, toilets, drinking water, bathrooms, etc. (9) Failure to arrange a complete training plan 3. Failure to make subordinates do their best (1) Failure to guide subordinates on how to do their jobs (2) Failure to explain the work as much as possible to make them interested (3) Failure to show concern for the progress and personal life of subordinates (4) Failure to tolerate subordinates' mistakes (5) Failure to pay attention to the strength and personality of subordinates and assign work appropriately (6) Failure to study the differences of subordinates to maximize their potential (7) Indulge in the existence of factions or formation of small circles among subordinates (8) Evaluation A person only values qualifications, race, religion, relationship, region, etc. (9) Knowing that someone is mentally or physically unsuitable, but not mobilizing him (10) Still letting a sick subordinate work (11) Not providing needed assistance (12) Not giving promotion when possible and appropriate (13) Not considering issues affecting salary and working conditions (14) Not training a candidate 4. Lack of concept of standard working hours instruction 5. Lack of personnel Data on Efficiency Management 6. Waste of Accidents 1. Failure to realize that preventing accidents is part of the job 2. Failure to thoroughly explain safety matters to all subordinates 3. Failure to install safety protection on machines and ensure that they are effective 4. Condolence in the abuse of safety protection in the workplace 5. Failure to mark hazard signs in appropriate places and keep them clean and legible 6. Failure to fully understand the indirect costs of accidents 7. Poor placement of materials 8. Not understanding what constitutes an accident Causes of danger 9. Failure to keep accident records, analysis and application 10. Failure to establish good safety practices 11. Failure to conduct regular and practical safety inspections 12. Failure to consistently implement safety rules 13. Workers lack necessary safety equipment: such as gloves, safety belts, welding shields, etc. 14. Managers do not recognize their safety responsibilities and accident responsibilities 15. Failure to inspire and maintain safety awareness among subordinates to prevent accidents 16. Failure to communicate with others * * Or cooperate with the safety inspector of the insurance company 7. Waste of lack of cooperation 1. Failure to cooperate with other managers or departments 2. Failure to fully understand company policies and explain them to subordinates 3. Unable to deal with rumors intelligently 4. Shifting responsibility to other squad leaders, subordinates or supervisors 5. Failure to appropriately reflect the opinions of subordinates to supervisors 6. Indulging dissatisfied employees in inciting rebellion against the company's practices 7. Failure of managers to give due diligence 8. Failure to encourage an atmosphere of camaraderie and cooperation among subordinates 9. Managers rashly criticize company policies and individuals within the department 10. Failure to fully cooperate with management in the company’s educational activities, including apprenticeship training, bulletin boards, employee communications, proposal systems, etc. 8. Waste of space and organization 1. Improper discharge and storage of materials 2. Inadequate attention to the route plan of materials in the factory 3. Wrong placement of machinery and other permanent equipment 4. Allowing subordinates to leave hand tools, ladders, trolleys, etc. in the aisles and failing to keep the aisles clean 5. Failure to scrap materials 6. Cabinets, oil drums, material supply areas, etc. placed in inconvenient places 7. Allowing unused machines and equipment to occupy important space 8. Failure to repair floor slabs in time, The necessary space such as the roof is not used 9. Insufficient lighting, forming black spots and dead corners 10. Poor layout in the unit and failure to maintain order 11. Unnecessary materials are placed in the workplace, and the warehouse and the factory are not separated 12. Failure to pay attention to the importance of ordering things 13. Failure to educate and supervise the return and location of used items 14. Failure to thoroughly implement regular (daily, weekly, monthly) cleaning projects to permanently maintain