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Lean Management: Mudas in Industry

What is a molt? How does it affect my production process?

A muda, in the context of industrial production processes, is a task that is not adding value, nor does it generate a benefit or improvement in the process, i.e., it is a waste.

Its history dates back to the 1950s and 1960s, within the philosophy of Lean Manufacturing (then known as the “Toyota Production System”) developed by the Japanese automobile company Toyota.

The objective of this research focuses on eliminating waste to improve processes and thus be more efficient in management and production. It was the result of the need to find efficient ways to produce automobiles since World War II had just ended and they lacked all kinds of resources.

Muda is one of the key aspects of this philosophy, as it will focus on eliminating and identifying all tasks that are not adding value to the production processes. Achieving efficiency optimization and cost reduction.

What are the main changes?

Historically we detected 5, but then some more have been added and this list has been updated.

Mudas en la in

Overproduction molt
Considered the worst of all. This type of waste occurs when more products or services are produced than the customer needs or orders. Eliminating overproduction is crucial to avoid unnecessary inventory buildup and associated costs We will be devoting resources to managing products that we have notn such as space, personnel, movement, materials, etc., which have not been demanded.


Motion Moulting

Occurs when displacements are made
unnecessarily, or without
unnecessary, or without adding value to the product.
This can be for different reasons: there is no organization, an incorrect approach has been taken, poor management of personnel on the line…


Standby MoultAs its name indicates, it is the waiting of: people, machines or materialsfor to be able to continue with their task. Reduce This waste of time is vital to maintain a more efficient workflow.


Muda de Procesamiento

. Actions that are performed repeatedly on a process or unnecessary actions without adding end customer value. Example: Packing a product that will be unpacked in the next step.


Change of transport. When material or product is moved without providing any value. It is important to analyze workflows, quantities and frequencies to achieve optimal transport.


Change of defects: Defects and errors are intrinsically Muda. They do not add value and generate waste of various kinds: cost of the defective material, time to repair or manage the defect or material, reprocessing, etc.


Change of Stocks (Inventory): Eith regard to the first molt, it is the waste of space due to the excessive storage of materials, products in process or finished products. Reducing excess inventory levels helps minimize warehousing costs and improve production flexibility.


Unused talent

. Failure to utilize staff experience, knowledge and creativity.

That is why Lean Manufacturing focuses on the reduction of these quality failures, as well as their early detection.

From Geprom Part of Telefónica Tech, we help you to implement solutions to identify, control and minimize these wastes in your manufacturing processes and thus optimize efficiency and quality.

Do you want us to help you implement solutions?