Find hidden waste across teams, steps, and handoffs. Quantify time, cost, risk, and improvement priorities. Turn messy process observations into focused, measurable action plans.
Use the weighted fields to reflect urgency, safety impact, customer pain, or strategic importance.
| Metric | Example Value | Unit | Purpose |
|---|---|---|---|
| Units Processed | 1200 | units | Observed output volume for the analysis window. |
| Actual Cycle Time | 18 | minutes per unit | Used to estimate overproduction and inventory exposure. |
| Waiting Time | 820 | minutes | Measures queue, idle, or approval delay losses. |
| Defect Rate | 3.5 | percent | Feeds rework and scrap cost calculations. |
| Weight: Waiting | 5 | priority factor | Raises urgency where delays damage service most. |
1. Available Minutes
Available Minutes = Analysis Days × Workers × Hours per Day × 60
2. Cost per Minute
Cost per Minute = (Labor Rate per Hour + Overhead Rate per Hour) ÷ 60
3. Defects Minutes
Defects Minutes = Units Processed × Defect Rate × Rework Minutes per Defect
4. Defects Cost
Defects Cost = (Defects Minutes × Cost per Minute) + (Defective Units × Scrap Cost per Defect)
5. Overproduction Cost
Overproduction Cost = Overproduction Units × ((Actual Cycle Time × Cost per Minute) + Material Cost per Unit)
6. Inventory Cost
Inventory Cost = (Inventory Units × Actual Cycle Time × Cost per Minute) + (Inventory Units × Inventory Days × Holding Cost per Unit per Day)
7. Total Waste Cost
Total Waste Cost = Sum of all waste category costs
8. Flow Efficiency
Flow Efficiency = Value-Added Minutes ÷ (Value-Added Minutes + Total Waste Minutes) × 100
9. Priority Score
Priority Score = ((0.70 × Minutes Share of Capacity) + (0.30 × Cost Share of Total Waste)) × 100 × Weight
This method blends time impact, financial effect, and strategic weight. It is useful for ranking improvement targets quickly across many processes.
It measures the eight classic lean wastes using time, cost, and weighted priority. The output helps rank improvement targets instead of showing only one raw total.
Weights let you reflect business importance. A waste with moderate minutes but severe customer impact can outrank a larger waste with less operational risk.
No. It is a practical blended scoring model. It combines capacity loss, waste cost share, and your weight setting to support faster decision making.
Use direct observation, time studies, queue reports, ticket aging, or machine downtime logs. Keep the period consistent with the analysis days field.
Yes. Replace unit output with cases, tickets, jobs, documents, or transactions. The waste logic still applies to delays, defects, excess handling, and underused talent.
It is a simple planning estimate. It shows what savings might look like if the current waste cost falls by one quarter.
Include it when overproduction or scrap creates real consumption cost. For knowledge work, you can set material cost close to zero.
Review weekly or monthly for stable operations. For improvement projects, review after each change cycle to confirm whether the top waste actually falls.
Important Note: All the Calculators listed in this site are for educational purpose only and we do not guarentee the accuracy of results. Please do consult with other sources as well.