By Theodore Harris | Clear Route Consulting
Ever looked around your workplace and thought, “There’s got to be a better way to do this”?
You’re probably right—and chances are, you just spotted operational waste.
Let me give you a quick real-world example from a project I worked on.
The 300-Foot Label Run
At a retail distribution center I consulted with, I noticed one of the packers walking about 300 feet—every single time they needed to grab a shipping label. They did this all day, every day.
That one small inefficiency was costing hours of labor each week. The fix? We moved the printer closer. Just like that, the employee saved time and energy, and the process became more efficient.
That’s operational waste. It’s usually not flashy, but it adds up—and fast.
What Is Operational Waste, Really?
Operational waste is anything that eats up time, energy, or resources without adding value to the customer.
In Lean Six Sigma, we break this down using TIMWOODS:
- Transportation – Unnecessary movement of materials
- Inventory – Holding more than what’s needed
- Motion – Excess movement by people
- Waiting – Delays, downtime, or bottlenecks
- Overproduction – Making too much, too soon
- Overprocessing – Doing more than what’s required
- Defects – Errors that lead to rework
- Skills – Not using your team’s full potential
How to Spot Waste in Your Operation Today
You don’t need a fancy title to start identifying waste. Here’s how you can start right now:
- Watch the work happen – Pick one task or process and observe it from start to finish.
- Ask why – Why is this step here? What happens if we remove or adjust it?
- Sketch it out – A quick process map can help reveal bottlenecks and gaps.
- Talk to your people – Your team knows where the time gets wasted and where the frustration lives.
Don’t Just Find the Waste—Fix It
At Clear Route Consulting, I help teams uncover hidden waste and implement simple, practical fixes that actually stick. From 5S walk-throughs to full Operational Waste Assessments, I’ve got toolkits and hands-on sessions that get results.
If you’re in Ohio, I even offer on-site walkthroughs to help your team take the first step toward a smoother, more efficient operation.
Let’s Make Your Operation Work Better
Waste doesn’t fix itself. The longer you wait, the more money, time, and energy you lose.
I’ve seen firsthand how a few small changes can completely shift how a team performs. If you’re ready to stop spinning your wheels, let’s connect.
👉 Shoot me a message or check out the Operational Waste Toolkit to get started.