Production environments that aim to optimize efficiency often use the TIMWOODS model. Behind the TIMWOODS acronym lie the eight major forms of waste in Lean methodology. In this article, we will explore how the TIMWOODS model works and highlight the benefits it offers -along with a breakdown of each of the eight types of waste.
What is the TIMWOODS model?
The TIMWOODS model is closely linked to Lean thinking and is an essential part of Lean management. Lean is all about continuous improvement by, among other things, eliminating waste – and the TIMWOODS model defines the eight most significant types of waste in this context. In manufacturing, TIMWOODS and Value Stream Mapping are two of the most widely used methods to identify and eliminate inefficiencies in processes. Applying these tools within an organization helps boost efficiency and reduce costs, ultimately improving both operational performance and customer satisfaction. TIMWOODS is commonly used in production, logistics, and service industries.
What are the eight wastes in lean?
The acronym TIMWOODS represents the eight forms of waste identified within Lean methodology. Each letter stands for a specific type of waste that can reduce efficiency and increase costs. When we break down TIMWOODS, we get: Transportation, Inventory, Motion, Waiting, Overproduction, Overprocessing, Defects, and Skills underutilized. Below, we explain what each type of waste entails and how they can be addressed.
Transportation
Moving people, inventory, products, or components from one place to another consumes time – and if not managed carefully, it can lead to unnecessary delays and added costs. For example, excessive or poorly planned transport routes, or workstations that are not logically connected in the workflow, can slow down operations and increase expenses. To reduce this form of waste, fixed delivery routes and scheduled time slots can be implemented to prevent unnecessary or duplicated trips to the same location.
Inventory
Holding too much inventory is another key form of Lean waste. Excess stock takes up valuable physical space and ties up capital that could otherwise be invested elsewhere. It also extends lead times and may require extra handling or maintenance to preserve product quality. By closely monitoring the balance between supply and demand, you can avoid overproduction and prevent inventory from sitting idle for too long.
Motion
Unnecessary movements – whether by people or equipment – also constitute a form of Lean waste. These motions can lead to lost time, increased safety risks, and reduced process efficiency. This includes employees walking unnecessarily between stations, as well as equipment being moved without real need. One effective solution is to optimize workplace layout so that all required materials and tools are always within easy reach, minimizing unnecessary motion.
Waiting
Any time people, materials, or information are not available when needed, waiting occurs – leading to non-productive time. This is a significant waste in Lean, as that idle time adds no value. To reduce delays and improve lead times, standardized work instructions and daily planning schedules can be implemented. This ensures that everyone knows what is expected, when, and where – helping the team stay aligned and avoid unnecessary downtime.
Overproduction
Closely related to inventory waste is overproduction. When more is produced than what the customer actually demands, excess stock piles up. This leads to higher storage costs and the risk that the product may no longer meet customer expectations by the time it is used or sold. Overproduction can also occur in office environments – for example, making too many copies, sharing unnecessary information, or writing reports no one asked for. Avoiding overproduction requires producing only what is needed when it is needed, supported by strong communication between the organization, the customer, and employees.
Overprocessing
Besides producing too much, performing unnecessary work is also a form of waste known as overprocessing. This occurs when an organization invests more effort or resources than the customer is willing to pay for. For example, adding extra process steps that do not increase customer value. It is therefore essential to thoroughly understand and continuously monitor customer needs and requirements to avoid both over- and under-investing.
Defects
When mistakes are made, products or components often need to be rejected or reworked. This wastes materials, time, and labour. Identifying the most common defects and addressing their root causes is key to reducing this type of waste. A system that detects deviations in the process combined with standardized work procedures helps prevent defects and improve overall quality.
Skills underutilized
Employees who have skills and knowledge that are not fully utilized, or who work in roles where their talents are underused, represent a frequently overlooked form of waste. This can lead to decreased motivation and productivity, and also means missing opportunities to improve efficiency and quality in other departments or processes. Regular communication with employees to explore opportunities and offering appropriate training are important to continuously develop and leverage their skills.
What are the benefits of the TIMWOODS model?
The TIMWOODS model offers several advantages when it comes to process improvement. Its main benefit is that it helps organizations systematically identify and eliminate Lean wastes, leading to more efficient processes. Addressing the TIMWOODS wastes enables teams to gain clearer insight into where money, time, and resources are being lost. This results in cost savings, increased productivity, and improved customer satisfaction. Additionally, the TIMWOODS model fosters team-oriented thinking and continuous improvement.
TIMWOODS model with the EZ-GO app
To digitally visualize TIMWOODS wastes within factory processes, the EZ-GO platform can be used. Employees can easily report wastes such as waiting times, defects, or overproduction through the app. These reports are immediately shared with the team, enabling swift action. The app also allows for registering, tracking, and visually presenting improvement points via dashboards. Moreover, EZ-GO supports the documentation and enforcement of standards, which is crucial for preventing defects and maintaining process quality. By making standards centrally accessible and visually clear, compliance becomes easier and more consistent for everyone on the shop floor. Using the EZ-GO platform thus makes adhering to the TIMWOODS model more accessible and structured.
Questions about TIMWOODS or lean wastes?
Do you have questions about the TIMWOODS model or about identifying and reducing lean wastes in your factory? Feel free to contact EZ Factory. Our team is happy to assist you with practical solutions to improve processes and make waste visible. With our EZ-GO app, we support operators and team leaders every day in performing their work efficiently.