A German production director spent five years identifying 151 types of waste in Chinese factories

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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 as many as 151 types of waste in Chinese factories... .In Edela’s management notes, we found dense but neat notes, and Mr. Edela also classified these 151 types of waste into eight categories... 1. Waste of time 1. Lack of proper planning, causing personnel to wait when changing specifications, or stop work for materials 2. The squad leader failed to fully understand the orders and instructions he received 3. Lack of understanding of the work content throughout the day 4. Unclear about the squad leader’s orders or instructions 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, causing overtime 7. Failure to inspect Whether the 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. Frustrated in filling out reports and various application forms 12. Allowing employees to develop bad habits such as chatting, leaving work without permission, and wasting time* Habits 13. Failure to inquire and correct the reasons for temporary absenteeism and leave 14. Failure to require employees to start work on time, lax supervision 15. Delay in decision-making 16. The monitor himself unnecessary requests for leave and being late or not punctual 17. Late submission of reports 18. Failure to immediately investigate the reasons when repairs are needed 19. Unnecessary conversations and inquiries at work 20. The monitor cannot properly arrange his work and time 2. Waste of creativity 1. Failed to listen to employees' suggestions 2. Failed to encourage employees to make more suggestions 3. Failed to listen to subordinates' opinions on various issues 4. Failed to conduct extensive research on methods related to one's own work and business 5. Failed to ask new employees about their past work experience to obtain useful opinions 6. Failed to fully consult other departments (such as biotechnology, etc.) 7. Failed to consider or designate appropriate personnel to handle all useful proposals 8. Failed to obtain useful opinions from meetings 9. Poor management function 3. Waste of materials and supplies 1. Poor supervision, resulting in waste of materials 2. Insufficient guidance to new people 3. Insufficient guidance when assigning new work 4. Blueprints or sketches are damaged, difficult to understand, misread, standards are not corrected in time, or self-initiated 5. Mechanical failure or failure to adjust 6. Failure to check the use of materials in each process (standard and variance analysis) • Failure to let subordinates understand the value of materials or supplies • Unclear orders and instructions • Condoning poor material handling • Failure to pay attention to the eyesight and health of subordinates, resulting in defective products • Lack of discipline, allowing careless or improper work • Allowing subordinates to use inappropriate materials, such as too good or too poor • Failure to trace the origin of bad work people, so that they cannot be corrected • Unable to apply the appropriate materials, especially newcomers • Requested too many materials, but failed to return the excess materials • Failed to request the correct materials, used the wrong materials • Failed to check whether the materials were arranged neatly and correctly placed • Failed to check for cracks and damage in steam, water, gas, electricity and compressed air pipelines and wires • Indulged in subordinates' personal use Oil, compressed air, gadgets, chemicals, etc. • Allowing defective materials to flow into the process as good products • Lack of effective systems to prevent materials from flowing out, loss or theft • Treating reusable materials as waste • Condoning waste or abuse of the following supplies: brooms, stationery, tarps, light bulbs, water pipes, etc. • Failure to stop production immediately when defects occur 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 breakdowns 3. The squad leader lacks the knowledge to use machines correctly and does not understand the capabilities of various machines 4. Failure to regularly inspect - ropes, Belts, chains, conveyor belts, lubrication systems, etc. 5. Use a machete to kill chickens, use big 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 exposed to 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 need to be made are not done immediately. 11. The machine does not have appropriate operating instructions. 12. Lack of good discipline to avoid abuse of the machine and equipment. 13. Allowing subordinates to use "improper methods" to repair the machine. 14. The foreman does not know the machine 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 machines 18. Machines that can be repaired are scrapped 19. There is no data for efficiency management (mechanical efficiency) 5. Waste of manpower 1. Unable to control personnel changes of capable subordinates due to the following reasons • Failure to assess the direct and indirect costs of employee changes • Too much "management" and too few smart leaders • "Too strict" or "too loose" discipline requirements • "Promises" that can be achieved, but not kept • "Promises" that cannot be kept, such as salary increases or promotions • Firing people without good reasons, and not Dismissal should be used as a punishment • Forcing subordinates to stay in jobs that they extremely dislike • Treating subordinates unfairly • Taking sides when subordinates quarrel • Commenting on one subordinate at other subordinates (referring to Sang scolding Huai) • Failure to find out the reasons for voluntary resignation of subordinates • Unable to correctly explain the company's goals and policies to subordinates • The monitor did not participate in employee salary adjustments • The monitor's authority is not good 2. Failed to enable new employees to fully exert their productivity, failed to accept new employees in a friendly and helpful manner; failed to provide safe work guidance to new employees; failed to let new employees understand the full-day work and other contents; failed to select qualified people to cooperate with the work; failed to educate new employees * Slow people are impatient. They fail to encourage other subordinates to show a friendly and helpful attitude towards newcomers. They do not get as close to newcomers as possible. They fail to inform newcomers of factory life conditions and plans, such as safety, pay dates, toilets, drinking water, bathrooms, etc. They fail to arrange a complete training plan 3. Failure to make subordinates do their best • Failure to guide subordinates on how to do their jobs • Failure to explain the work as much as possible to make them interested • Failure to show concern for the progress and personal life of subordinates • Failure to tolerate subordinates’ mistakes • Failure to pay attention to the strength and personality of subordinates and assign work appropriately • Failure to study the differences of subordinates to maximize their potential • Indulging in the existence of factions among subordinates Or forming a small circle • Evaluating a person only based on qualifications, race, religion, relationship, region, etc. • Knowing that someone is mentally or physically unsuitable but not mobilizing him • Still letting a sick subordinate work • Not providing needed assistance • Not giving promotion when possible and appropriate • Not considering issues affecting salary and working conditions • Not training a candidate 4. Lack of concept of standard working hours education 5. Lack of data on personnel efficiency management 6. Waste of accidents • Failure to recognize that preventing accidents is part of the job • Failure to explain safety matters thoroughly to all subordinates • Failure to install safety guards on machines and ensure that they are effective • Condolence in the misuse of safety guards in the workplace • Failure to mark hazard signs in appropriate places and keep them clean and legible • Failure to fully understand the indirect costs of accidents • Poor placement of materials • Not understanding the hazards posed by accidents Causes of risks • Failure to keep accident records, analysis and application • Failure to establish good safety practices • Failure to conduct regular and practical safety inspections • Failure to consistently implement safety rules • Workers lack necessary safety equipment: such as gloves, seat belts, welding shields, etc. • Managers do not recognize their safety responsibilities and accident responsibilities • Failure to inspire and maintain the safety awareness of subordinates to prevent accidents • Failure to communicate with others * * Or cooperate with the safety inspector of the insurance company 7. Waste of Lack of Cooperation • Failure to cooperate with other managers or departments • Failure to truly understand company policies and explain them to subordinates • Failure to handle rumors intelligently • Shifting responsibility to other squad leaders, subordinates or supervisors • Failure to appropriately reflect subordinates’ opinions to supervisors • Indulging disgruntled employees in instigating rebellion against company practices • Failure of managers Give full support to those company regulations that are not yet popular • Fail to inspire an atmosphere of camaraderie and cooperation among subordinates • Managers rashly criticize company policies and individuals within the department • Fail to sincerely and 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 • Improper discharge and storage of materials • Insufficient attention to the routing of materials in the factory • Incorrect placement of machinery and other permanent equipment • Allowing subordinates to leave hand tools, ladders, trolleys, etc. in the aisles and failing to keep the aisles clean • Waste materials not being scrapped • Cupboards, oil drums, material supply stations, etc. placed in inconvenient places • Allowing unused machinery and equipment to occupy important space • Due to failure to repair floors, roofs, etc. in a timely manner, the required space is not utilized • Insufficient lighting, forming black spots and blind spots • Poor layout in the unit and inability to maintain order • Unnecessary materials are placed in the workplace, and the warehouse and workshop are not separated • Failure to pay attention to the importance of ordering things • Failure to educate and supervise the return and location of used items • Failure to thoroughly implement regular (daily, weekly, monthly) cleaning projects to permanently maintain sources: network