At Jendamark, we build component assembly systems that drive efficiency, but we know machinery alone cannot fix a broken process. In a recent podcast session with Vitor Ferreira, a lean manufacturing veteran with decades of experience at Michelin and Bridgestone, we unpacked why unused human talent destroys productivity. Here is how you can use this professional tool to reduce waste and streamline your business processes.
Understanding the 8 wastes: What TIMWOODS representsnverter Work
The Toyota Production System (TPS) originally identified 7 wastes (or muda). Developed by Taiichi Ohno, these seven wastes formed the backbone of lean manufacturing. Later, Lean Six Sigma practitioners added an eighth – Skills – to address the waste of human potential, which quietly keeps the other seven alive.
TIMWOODS is a mnemonic device that helps you remember these 8 types of waste. Here is how the acronym corresponds to the common wastes found in manufacturing (and how unused human talent makes them worse).
T – Transportation waste
Transportation waste is the unnecessary movement of materials. Every time you move a pallet, you risk damaging it. You pay for the forklift, the fuel, and the time, but you do not add value to the customer. If parts travel back and forth across the production process, you have a layout problem. But an operator might know that moving a bin five feet closer saves an hour a week. If you ignore their input, that waste remains.
I – Inventory waste
Inventory waste creates a false sense of security. Managers stock raw materials and parts “just in case” something goes wrong. Ferreira calls this “garbage”. In our discussion, he noted that carrying inventory often costs a business 20 to 30% of its value annually. If you hold stock that doesn’t move, you are dealing with high storage costs and paying rent on waste. The team on the floor knows exactly which parts gather dust and create storage costs. Listen to them.
M – Motion waste
Unnecessary movement of people kills momentum. This is different from transportation. This is your operator walking five steps to grab a tool that should be within reach. Wasted motion exhausts people and increases the time per cycle. Lean principles demand that we bring the work to the person, not the person to the work. Operators feel this pain – and you pay for their steps.
W – Waiting waste
Waiting waste is the most frustrating form of waste for workers. It occurs when an operator suffers idle time because of downtime, missing parts, or delayed instructions. According to a study on manufacturing efficiency, unplanned downtime costs industrial manufacturers an estimated $50 billion annually. Waiting is money burning and engaged employees can suggest schedule tweaks to smooth the flow.
O – Overproduction
Overproduction is often called the “mother of all wastes”. It involves producing more products than customer requirements demand or producing them too early. Overproduction leads to excess inventory, adds storage costs, risks obsolescence, and consumes time and resources you might need elsewhere. Operators can see the glut forming before your spreadsheet does.
O – Overprocessing
Overprocessing happens when you do work beyond what is required to add value. This includes painting unseen parts, running unnecessary reports, or using a high-precision tool when a simple one would do. If the customer is not willing to pay for it, stop doing it. major problem.
D – Defects
Defects result in rework, scrap, and dissatisfied customers. A defect disrupts the workflow and forces you to spend money fixing what should have been right the first time. Defects kill customer satisfaction. Unused skills mean operators might lack the training or authority to stop the line when a defect appears. See how we tackled error-proofing in our tractor engine assembly case study.
S – Skills (non-utilised talent)
This happens when management fails to engage staff at all levels in problem-solving. Ferreira calls this the silent waste because operators know the work processes better than anyone. If you ignore their ideas, you create waste in their processes. When you eliminate the waste of unused human talent and ingenuity, you gain thousands of eyes looking to eliminate waste across the board.
How to conduct a TIMWOODS walk
Identifying and eliminating these wastes requires you to go to the Gemba (the place where work happens). TIMWOODS is a tool designed for the factory floor, not the office. Ferreira suggests a simple 30-minute routine to identify wastes:
- Stand in the circle: Pick one station. Watch 2-3 cycles without interrupting.
- Use the checklist: Look for TIMWOODS waste. Are they searching for tools (Motion)? Are they waiting for a machine (Waiting)?
- Ask questions: Ask the operator, “What gets in your way the most?” and “How would you improve processes?”
- Fix the workplace: Often, a lack of 5S drives the amount of waste. If tools used don’t have a home, motion waste is inevitable.
You can read more about why digital and lean initiatives fails without this cultural observation, and the data to back it up, in our article on why smart factories are not working.
The hidden cost of “just in case”
The biggest barrier to waste elimination is fear. We tolerate overproduction and excess inventory because we are afraid of running out. Trust your lean system and your people.
Lean methodology aims to remove the rocks from the river so the water can flow. When you eliminate waste, you expose the root cause of your instability. This allows you to improve processes permanently rather than just coping with them.
Lean manufacturing and the future
TIMWOODS stands as a critical lens to see your factory clearly. Whether you are pursuing Six Sigma certification or just trying to reduce costs, the 8 wastes of lean exist in your process.
TIMWOODS provides the roadmap to build a culture of continuous improvement, where people understand the purpose, feel safe to point out waste, and offer solutions.
If you are ready to build a system that minimises waste by design, we can help. Jendamark provides the world-class assembly systems and digital solutions you need to drive productivity.
