♻️ In Lean Manufacturing, eliminating waste is key to increasing efficiency and reducing costs. The Lean system identifies 8 types of waste (muda) that do not add value to the final product and must be continuously combated.
“Waste is anything that the customer does not want to pay for.” – Lean Principle
📦 The 8 Wastes of Lean
1. Overproduction
Producing more than necessary or faster than the pace of demand (Takt Time).
🛠 Example: DUTs tested before there is space or need.
2. Waiting
Time lost waiting for material, tools, approvals, or test results.
🛠 Example: operator standing idle waiting for bench or software release.
3. Transportation
Unnecessary movement of materials, parts, or DUTs between areas or stations.
🛠 Example: manually moving DUTs from one station to another instead of using continuous flow.
4. Overprocessing
Unnecessary or redundant steps that do not add value to the product.
🛠 Example: manually retesting a DUT that has already been automatically approved.
5. Inventory
Excessive accumulation of inputs, parts, or WIP (Work in Progress).
🛠 Example: DUTs waiting for testing accumulated in boxes or racks.
6. Motion
Unnecessary movements by operators that cause fatigue and time loss.
🛠 Example: fetching tools or cables far from the test station.
7. Defects
Errors that cause rework, scrap, or the need for diagnosis and repair.
🛠 Example: DUT failure due to poor connection in the fixture or lack of visual inspection.
8. Unused Talent
Waste of knowledge, creativity, and skills of employees (point added later to the original Lean model).
🛠 Example: technicians with improvement ideas ignored or operators not trained to suggest improvements.
🎯 How AJOLLY Testing Helps Reduce Waste
AJOLLY Testing designs test and automation solutions focused on minimizing each type of waste:
- Dashboards with WIP and cycle time indicators
- Benches with automatic Takt Time control
- Elimination of rework through early failure detection
- Ergonomic design of jigs and stations (5S and NR-12)
- Digital traceability that reduces inventory and improves flow
- Technical training and involvement of test teams
Eliminating waste is increasing value. It’s doing more, with less time, less effort — and with more intelligence.