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By connecting the processes you can avoid transportation. This also helps to cut out inventory since material can be moved downstream to the next process sooner. There is less need for work in process (material waiting to be moved). If the process speeds can not be balanced right away or if there is a changeover or other factor that causes a batch process it is still possible to bring the processes closer so that transportation is limited and Visual Management is improved. The customer only wants to pay for the minimum effort necessary to make their product. The quickest and simplest way to fulfil the customer’s request is to start working on the job and keep it moving continuously until it is finished. The less transportation, queuing, and scheduling work that is involved the smoother it will be. Just in Time production allows you to design your process so that the workflow can be direct and connected. There are two pats to overproduction. It can be making too much, or making the right amount but making it too early. In both cases it is overproduction (the opposite of just in time). What causes overproduction waste? Just-in-case thinking Misuse of automation Long set-up times Inadequate forecasting Keeping busy Using up extra materials Local optimization vs. overall optimization What Lean tools can we use to prevent overproduction? Kanban Visual Management Quick Changeover One-piece flow lines Takt time production Overproduction is the biggest waste for two reasons. First, because you are producing more of something that you do not need, you are not producing enough of something you do need. That means that you will miss the opportunity to sell something because you are too busy being “efficient” at producing something else. It is better to produce the right mix and sell everything you make rather than make things you won’t sell very quickly. This lost opportunity cost can be a major loss and a limiting factor on growth for many companies. The secon