Toyota 8 Wastes Self-Audit
Score each waste 1-5 (1 = pervasive problem, 5 = no issue). Enter your annual revenue to convert severity to dollar impact (typical loss = 5-15% of revenue per waste category).
| Waste | Description | Score 1-5 | Est $ Loss |
|---|---|---|---|
| Defects | Rework, scrap, customer complaints | -- | |
| Overproduction | Producing before customer demand | -- | |
| Waiting | Idle people / equipment | -- | |
| Non-Utilized Talent | People doing work below their skill | -- | |
| Transportation | Moving material more than necessary | -- | |
| Inventory | Excess raw / WIP / finished | -- | |
| Motion | Excess people movement at station | -- | |
| Extra-Processing | More work than the customer pays for | -- |
How this works
The eight wastes are Toyota Production System's diagnostic checklist. The standard Lean acronym is DOWNTIME: Defects, Overproduction, Waiting, Non-utilized talent, Transportation, Inventory, Motion, Extra-processing.
The $-loss bands here use a benchmark of up to ~3% of revenue per category at the worst score, scaling to zero at the best. These are typical ranges from Lean literature; pressure-test against your own value-stream map.
About this tool
Part of the Business Operator's Blueprint companion toolkit. The full guide (250+ pages, $79) maps every operating-system framework Phil Baratelli has tested across hospitality, manufacturing, distribution, and capital allocation. Get the guide →
Baratelli Institute · Philip A. Baratelli, CPA, MBA · baratelliinstitute.com