The basics of motion waste 

In manufacturing, efficiency is crucial for business success. And while you may have already detected the main culprits standing in the way of streamlined operations, sometimes the biggest barriers aren’t the obvious bottlenecks or production delays. Smaller, sneakier every day actions might have a bigger impact than you given them credit for. 

Think of your workforce constantly walking back and forth to grab tools or twisting and turning to reach awkwardly placed controls. Individually, each of those movements holds little significance, but collectively, they drain on productivity, energy, and even worker safety. This is what motion waste is all about.

Luckily, by better understanding what motion waste is, you can also learn ways to reduce it and unlock your full business potential.

What is motion waste?

In simple terms, motion waste refers to all the extra movement your employees do that doesn’t actually contribute to overall productivity.

For example, on an assembly line, if workers constantly walk back and forth to get the parts they need, this contributes to motion waste. Similarly, if tools are not comfortably within their reach, this could cause excessive strain — and in worst-case scenarios, even an accident or injury.

Motion waste is among the inefficiencies targeted by lean manufacturing, an approach focused on maximizing productivity by removing any activity that doesn’t add value. This includes inefficient motion, along with: [1]

Eliminating unnecessary or excessive movement in your operations can bring the following benefits:

When tools, supplies, and equipment are easily accessible by being close to workstations, your employees spend less time searching or moving unnecessarily and more time focused on tasks that create value. This not only improves overall efficiency but also minimizes their physical strain during the workday.

Reducing motion waste also sends a clear message to your teams that their time, comfort, and wellbeing matter. When people feel supported in their roles, morale improves — and that has a direct impact on performance. In fact, a study by the Social Market Foundation found that happy workers can be up to 20% more productive than unhappy ones. [2]

2. Enhanced health and safety

Manufacturing facilities naturally carry safety risks, with moving machinery and intense manual labor taking place in fast-paced, complex environments. So, minimizing workplace safety hazards is essential, and trimming motion waste can play a key role in achieving this. That’s because reducing unnecessary movement lowers exposure to physical and ergonomic hazards, helping keep your teams safer.

3. Cost savings

While the effects on your bottom line might not be immediately obvious, increasing efficiency by reducing motion waste makes your investment go further in the long term. Simply put, if workers can focus more on value-adding tasks instead of walking to retrieve tools, parts, or cleaning supplies, you’ll gain more productivity for every dollar you spend. 

Think about it this way: if your employees are constantly hunting for materials because your facility isn’t laid out properly, that lost time adds up fast. Across a whole team, those small delays can easily turn into hours of wasted effort every week — and over months or years, that means a lot of money slipping through the cracks in unproductive labor.

How to reduce motion waste in your manufacturing facility

Now that you’re more familiar with what motion waste is and how reducing it can benefit your business, let's explore some effective ways to achieve smoother workflows, safer operations, and greater productivity on the shop floor and beyond:

Perform a motion waste assessment

The first step to cut down on motion waste is to identify where it is happening. This involves observing your employees as they carry out their tasks, mapping workflows, and noting any unnecessary or repeated movement. During this research, it’s important to pay close attention to: [3]

• How often workers leave their stations and why. 
• How long it takes for them to retrieve tools and supplies.
• What distances on the line could be shortened. 
• Whether disorganization or poor layout causes delays. 
• Whether operators are straining to reach tools, parts, or controls.
• If wasteful movement is causing workplace hazards.

Once these inefficiencies are clearly diagnosed, you can prioritize areas for improvement and implement changes that make work smoother, safer, and more efficient.

44% of workers are interrupted at least 20 times during a workday to fetch or dispose of wipers or cleaning tools*, yet this is an often overlooked dimension — and a great place to start. To get a better idea of how big of an impact motion waste has on your everyday operations, check out our motion waste calculator. All you need to do is answer a few simple questions to discover the scale of motion waste in this area of your facility and we’ll provide you with helpful resources to tackle it. 

Another effective way to improve your company's processes and help reduce unnecessary wiping and cleaning movements is with Tork Workflow™. This free service connects you with a Tork expert who reviews your facility’s workstation setup and efficiency. The assessment focuses on key areas like motion waste and gives you practical product solutions — such as Tork wipers and cloths — to streamline your operations. 

On top of observing your workforce in action and leveraging Tork tools and resources, consider conducting interviews with your teams. That way you can learn first-hand what matters to them most and how you can improve their wellbeing and productivity.

Place supplies strategically

When you keep resources close to where they are used, your employees can grab what they need without extra steps or wasted effort. A successful placement strategy could include:

• Keeping tools and parts at points on the production line where workers need them most.
• Positioning wiper and cloth dispensers in areas that are prone to spills, like near machinery that could drip oil and grease. Consider how proximity to cleaning tools helps encourage regular preventive maintenance as well.
• Placing hygiene stands equipped with hand sanitizer near machinery for quick hand hygiene.
• Ensuring safety equipment 

If everything they need is within reach, your employees can focus on performing their tasks efficiently and safely.

Adopt the 5S methodology

The 5S methodology is a cornerstone for reducing all seven inefficiencies in lean manufacturing, including motion waste. Let's take a look at its five key pillars:

3. Shine

Maintain cleanliness in your factory — this helps workers quickly spot misplaced items or hazards that could cause motion waste.

Handling large or bulky items without assistance can easily lead to motion waste. This might mean spending extra time moving materials, making multiple trips to unload shipments, or putting unnecessary strain on your workers. That's where equipment like carts, trolleys, conveyors, lift tables, and hoists come in handy.

By strategically placing such aids along production lines or storage areas, your employees can carry supplies smoothly without retracing steps or transferring materials manually. Along with boosting efficiency, these tools reduce the risk of repetitive strain injuries and accidents from awkward lifting or overexertion, creating a safer and more ergonomic workplace.

Train your employees

When it comes to minimizing waste of any type in any facility, everyone has a part to play. Therefore, training is key to teach your operators how to reduce unnecessary movement and why it's important. You can do this through physical demonstrations and workshops on how to keep their production cells organized, return tools to their proper place, and use material handling systems efficiently and safely. You could even encourage your teams to provide feedback on workflow bottlenecks or awkward layouts to help identify specific topics that they are struggling to manage effectively. Involving them from the start of the learning process is a great way to keep your workforce engaged and ensure consistent execution.

In a nutshell, reducing motion waste is crucial for creating a sleeker, smarter business. By cutting out unnecessary steps, you can save time, reduce strain on employees, and boost overall productivity. The best part? Many fixes are simple, like keeping cleaning supplies at hand or standardizing procedures, yet they deliver lasting benefits. You’ll likely not only see efficiency gains but also create a work environment where people can focus on what really matters: getting the job done.

Want to take your facility to the next level? You can learn even more about motion waste in our guide on reducing motion waste in your business. You can also check out our resources on sustainability in the manufacturing industry to understand how being more mindful of our planet can benefit your operations.

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