That smacks way, way too much of the waterfall and the factory for my taste, and it’s weird to hear it coming from so many Agilists. There are many techniques out there to help you to identify and eliminate wastes; however within lean manufacturing we wish to prevent them occurring in the first place. MB < Was the first approach defective? Trending and deducting release dates from defect density is plain idiotic, when with a little attention to defect prevention defects would be so rare that trends would not exist.

Much of this is based on the the fact that…, 2) The concept of “defects” is muddy and unhelpful (mostly for reasons I outlined in my first comment). Based on the definition of defect on this very post, the programmer is re-factoring a previously working solution, hence he is not fixing a defect as such but he is improving the efficiency and maintainability of the code without changing the business value.

That’s okay. We researched for you what the most frequently occurring types of waste are that can be found at construction projects. Whether a) it existed, b) didn’t exist, c) it was a Schrodinger defect that existed and didn’t exist at the same time is NOT important and discussing it over and over is guess what> Overprocessing. If you asked another programmer, would she say so? In addition to the obvious cost of the initial scrap item we have a number of other costs that are not always obvious or considered although frequently far in excess of this initial cost. Should we build all that waste because we might be affected by that one strange case or could we fix everything immediately and have an exception for a rare category of defects? It is just how she was used to work. Removal of the waste of defects and the other wastes of lean manufacturing will help you to achieve these goals; Your email address will not be published. 2. It is probably the most common and most damaging type of waste that organizations encounter. Other activities that don’t produce value are Overprocessing.

Picking one defect to focus on, you then (second) add the ability to detect the defect such that defects don’t move to the next step in the manufacturing process compounding the loss of value. MB Example of developer changing his mind. An example of how Smart Factory Analytics can be used to minimize or eliminate defects is presented in this smart baker case study: hbspt.cta._relativeUrls=true;hbspt.cta.load(3418759, '8922e21b-fb69-47dd-a048-28f6d58d42c8', {}); The eight wastes of lean manufacturing can be remembered with the acronym DOWNTIME: hbspt.cta._relativeUrls=true;hbspt.cta.load(3418759, 'a7c47554-43e3-46db-bf57-7a07cc16bf7d', {}); Read Types of Waste in Lean Manufacturing - Part 2 - Overproduction Waste, Types of Waste in Lean Manufacturing - Part 1 - Defects Waste, a lack of standards or poor documentation, undocumented design changes that don’t marry to related parts, poor inventory control leading to ad-hoc manufacturing process adjustments. Every week I had to prepare defect charts for management. All your lecture on semantics can be forgotten because it was a lecture that you insisted in giving me even after I removed any trace of the name that had created the earthquake. After lunch on that same day, while having coffee, he realizes that he was all wrong all along. Nobody gave a damn about the dashboard, nobody used the numbers for any reason, nobody cared that they could configure it, but my boss was extremely proud of it. Epidemic indeed!

Fixing it now, means normally that the developer is fresh on the specific code that needs to be fixed, certainly fresher than in 4 weeks when he won’t even remember he ever wrote that code. Another bad characteristic of defects is that they can be easily counted and you will always find a pointy haired manager that decides he is going to shed light on the health of his product and on the efficiency of his test team by counting and drawing colourful waste charts. Our customers were normally unhappy because instead of focusing on value delivery we focussed on playing with defects, what a bunch of losers we were!

Want Your Colleagues To Do A Good Job? Lean practitioners also count the cost of inspection as part of this waste (although you shouldn't reduce inspection unless you've created perfect quality through mistake proofing techniques).Here are a few examples from various industries: 1. What if customers could read their orders on a screen as operators are inputting their order into the computer?

This activity could easily take 30% of the tester time.

Misdiagnoses in healthcare 2.

Instead, let’s think in terms of problems—situations that are undesirable to some person, and probably solvable by some person, although probably not without some effort. For a long time, discussion centered around only the prior seven wastes of Lean, but more recently, the waste of human potential has joined their ranks and with good reason. Here are some practical examples of each. Pingback: Lean is Good Customer Service | Lean Blitz – Do it better. How can supplies be tested (i.e. Excess inventory results in a waste of space, and it wastes the cost associated with the physical inventory.

5) I’m opposed to empty slogans “defects are waste” when they oversimplify complex systems of behaviour, learning, and development. You haven’t said what you meant by “waste,” so I’ll ask again: what are you saying? There are many approaches available to development teams to reduce the amount of rework needed.

Some problems simply aren’t simple. Reward for the wrong reason.

She called it the product quality health dashboard, I secretly called it the dump. I think you might mean “nobody like harping on defects”, or “nobody wants to talk about defects”.

Defects can be caused by many different problems, many that should be avoidable with a little thought when designing your products, processes and equipment. Toxic waste results from industrial, chemical, and biological processes. 3) Given that the programmer might have pondered the problem for several days before arriving at the second solution, can we say that the morning’s effort was wasteful? The vendor gives me a Coke with no ice. When someone asks a difficult question, we need—in my view, at least—to rise to the challenge and answer it.

Parts assembled with the incorrect orientation. So what DO you mean? It is normal for a developer to fix a defect he finds in the code he is writing as soon as he finds it without having to log it, but as soon as the defect is found by a different individual (a tester for example) then apparently we need to start a strict logging process.

Nice post, thanks for taking the time to put it together & sharing. The consequence of that conversation (that in some cases can involve also a product owner) should be let’s fix it now or let’s forget about it forever. It is certainly not an empty slogan, there is plenty of literature about it. Human energy is possibly incorporated. The defect waste is defined as the loss of value do to the scrap, repair, or rework of a product that deviates from specifications. Today we start with the Lean waste defects.).

No, he performed 2 activities, coding and re-factoring. One obvious one is the needless waste of materials used to replace worn machines; another one could be the health resources for overburdened employees, who might not have needed them if motion had been minimized.

Am I infringing any law by using a different definition? I remember working with a talented QA in a small company (team size of 4).

Change ), You are commenting using your Facebook account. 2014 Masters | Masters Media Guide | Eisenhower Tree | Reprinting |Lean Blitz – Do it better. That smacks way, way too much of the waterfall and the factory for my taste, and it’s weird to hear it coming from so many Agilists. I will add a note on my blog where I refer to Ono’s 7 categories of waste to avoid misunderstandings. In Lean Manufacturing, waste is called Muda, waste in the Japanese language. One way to address this is the need to provide adequate staffing to handle the workload at the bottlenecks, which some managers may target as a source of monetary waste. Organizations don’t decide to take on the 8 wastes of Lean just because they are there. Example 1: Reward waste. @LeanBlitz on Twitter These were extracted from our monstrous defect management tool and presented in brightly coloured useless charts. And I guess still am . Although it is a significant concern in manufacturing, it occurs in other sectors as well. Goodbye, Unwanted TSA Naked Body Airport Scanners! The waste of inventory involves storing products or materials that are not needed at this time. Defects are one of the seven wastes of lean manufacturing or 7 mudas, defects are when products or service deviate from what the customer requires or the specification. MB That’s exactly the philosophy behind the waterfall: get it right the first time. Even writing this sentence took a good while, now think how much time it takes you to produce, detect, fix, recheck defects. Presentation on the Designated Hitter and Root Cause Analysis, ASQ Influential Voices: My Own Influential Voices of Quality. MB I’m opposed to empty slogans “defects are waste” when they oversimplify complex systems of behaviour, learning, and development. Additional Notes on Efficiency | Lean Blitz – Do it better. Tight collaboration between business and delivery teams helps teams be aligned with their real business goal and reduce the amount of unnecessary features. If flawless processes and perfect customer value are the goals, then an investment in improvement technology is the right call. The word “defect” has a specific meaning in legal contexts. Pingback: Imagery of Poka-Yoke | Lean Blitz – Do it better. Logging and managing defects is extremely wasteful as well, it requires time, energy and can among other things, endanger relationships between testers and developers. He put in place a plan that included free food all day and night and some pampering for the developers that needed to focus 100% on defect resolution. Required fields are marked *, Click here to access Free Lean Presentations. Now all of those resources have to be leveraged again to make a non-defective product, PLUS there’s the effort needed to either take apart the defective product for recycling or salvage. 4) If we’re not very, very good at detecting problems, we’re not going to be very good at preventing them. There are obviously a load of assumptions based on those stats (such as the RCA is correct) as I don’t have time to check each bug. You see it when: We’d like to challenge you to find specific examples of each of the 8 wastes of Lean within your organization.

Careers With IQPC | Contact Us | About Us | Cookie Policy. Change ), You are commenting using your Google account. I have done TDD for 10 years and it never occurred to me, I look forward to learning something new. Topics: But mainly, do the rest of the word care what you deprecated and what not?