Lean Glossary

3P

• Product Preparation Process - 3P is about rapidly designing product and production processes to ensure: capability, built-in quality, productivity and Flow-Takt-Pull.

5S

• Building Blocks for shop floor discipline and control; Sort, Sweep, Standardize, Self Discipline, Sustain.

Action Workout

• (Kaizen) A 3-5 day event with the teams focused on taking action and making changes quickly…Solving problems empirically, through physical simulation, observation and iteration.

Andon

• A visual device, usually a specialized light that operators use to call attention to an abnormality. The use of this is to request immediate attention and action to the problem.

Automation

• The use of machines working independently of manpower.

Autonomation

• The process of separating the work of man and machine characterized by: work not movement; quality built into the process; and visual management. (see Jidoka)

Cell

• The optimal physical layout or machines and manpower

Chaku-Chaku

• A method of conducting single-piece flow in which the operator proceeds from machine to machine (in a counter-clockwise fashion), taking a part from the previous operation and loading it in the next machine. Then taking the part just removed from that machine, checking it and loading it into the following machine…etc,…

Cycle Time

• The total time required for a task to be complete. Cycle time is process specific, and many cycle times will exist within an overall lead time of making a product

Flow

• Work done simultaneous to or in conjunction with transportation or conveyance. e.g. an assembly is moving down a line while a person is performing work, ⁽²⁾ a person acts as a conveyor carrying a part to the next machine in a Chaku-chaku fashion. The main purpose of flow is to quickly and continuously identify and eliminate waste.

Heijunka

• The process of level loading and sequencing the timing of customer demand for products or services.

Jidoka

• Jidoka (Autonomation): One of the 3 main principles of Lean, it has 2 main elements: 1) Stopping the process when an abnormality has been detected 2) Building “human intelligence” into machines or software, giving automation the ability to make a decision to shut down automatically in the case of an abnormality in order to stop defective products from flowing into the next process. Jidoka measures are incorporated in the assembly process by use of Andons and Pin-Pan-Pon; stopping when abnormality is detected.

JIT

• (Just in time): One of the 3 main principles of Lean, it’s the philosophy of production characterized by 3 elements – each must be present to ensure JIT functions properly. single piece flow, producing according to TAKT time, pulling of material from upstream process

Kaizen

• “Change for the better” or “Continuous Improvement” A hands-on process of short duration to develop iterative solutions, with each iteration an improvement on the last.

Kanban

• A method/device of pulling from previous processes in order to control material flow, cap inventory levels, and to take “pulse” of the customer.

Kitting

• Grouping component parts used in a process or build for ease of assembly. (see material presentation)

Lead Time

• The total time it takes the product to go from raw inventory to the finished product. Order to remittance lead time refers to the total time from when an order is placed until the finished product is shipped.

Material Presentation

• Introducing material to the line or cell in a manner that is easy and effective for the operator.

Model Line

• A strategically selected production line, intended to showcase deep lean concepts. A place to pilot, refine, and then transfer proven processes to other sections of the site. Use the same Model Line throughout assessment.

MUDA

• Any type of waste elements that add no value to the product: i.e. Waiting, Transporting, Over production, Excess Motion, Inventory Defects, Human Touches.

Poka-Yoke

• Mistake proof: usually refers to the use of fail-safe devices in the process in order to prevent defects from occurring and insure quality. When this ingredient is added to automation will yield autonomation. ( see Jidoka )

Process Router Analysis

• A study of the process and machine sequence for a group of similar parts. It can be used to standardize product flow for ease of cell implementations.

Process Quantity Analysis

• A study of the quantities demanded of different products produced at a work location. This picture of the volume and variety of products can be used to identify high impact areas to concentrate efforts or identify the need to use process razing to make products more similar.

Pull System

• System of manufacturing in which each process withdraws the parts it needs from the preceding process when they need them, in the exact standardized amount needed.

Queue Time

• The time a part sits waiting to be worked on.

Set-up, External

• Machine changeover steps that are performed while the machine is processing parts or off-line from production time.

Set-up, Internal

• Machine changeover steps that are performed while the machine is stopped during production time.
• A disciplined methodology to drive execution of top strategies
• Focuses resources on the vital few and establishes discipline for predictable execution of strategy

Shingijutsu

• A company founded by C. Nakao and K. Iwata, former employees of Taiichi Ohno, the creator of the Toyota Production System. The word Shingijutsu translates as “new technology” or “better way”.

Single Piece Flow

• Production system in which only one part at a time is processed or assembled and the work is verified before being sent along the production line to follow processes. The 2 elements of SPF are 1) a “Do” and 2) a “Check” or verification that the “Do” was done correctly. This introduces a feedback loop into the system.

SMED

• Single Minute Exchange Die (i.e., under 10 min) has become a title for the category of improvement devices used in manufacturing to allow for quick change over of machine/fixture set-ups.

Standard Operations

• The combination of people and machines required to accomplish production in such a way as to minimize waste and variation by establishing only 1 way to perform the process

Standard WIP

• Minimum and standardized amount of work in process required to perform operations

Standard Work

• Sequence of repeatable tasks that an operator performs.

Standard Work Sheet

• Shows the outline of work for each worker in a cell. Recorded on it are: Takt time, work sequence, standard WIP, quality checks, safety precautions, etc.

Standard Work Combination Sheet

• A table that clarifies how much time is spent doing manual work and traveling at each production process.

Strategy Deployment

• A disciplined methodology to drive execution of top strategies
• Focuses resources on the vital few and establishes discipline for predictable execution of strategy

Super Market

• A visual system that has a predetermined amount of inventory and all facets of 5s in order to detect abnormalities.

Takt Time

• The pace that is set for the system to operate at. Customers establish Takt Time…the following equation is used to establish it: Available production time / required production (fcst & act demand)..must be like units; e.g.,
• 1 shift = 1980 min/wk 1980 = 10 mim = Takt Time - fcst = 198 units/wk 198

TPM

• Total Productive Maintenance is the total involvement of all employees in a cell to improve the process.

Value Stream

• The specific activities required to design, order, and provide a product from concept to launch – order to delivery – raw materials to finished goods.

Value Stream Mapping

• The process of detailing the process of converting raw material to finished goods. This is typically mapped with the 7 flows (info, people, equipment, raw material, sub-assembly, assembly,engineering) one at a time, or in a combination.

Visual Management

• Refers to the means by which anyone can tell at a glance if production activities are proceeding normally or not. A communication, discipline and pacing tool.

Waiting Time

• The time that a worker is idle when no work is available.

WIP

• Work In Process; inventory of materials that has been already started processing.

Work, Non-value added

• Rework, set-ups, inspection, repair processing, transportation, unnecessary work to complete the manufacture of a product. Anything that isn’t directly changing the form fit or function of the part.

Work, Value Added

• Only necessary direct work to manufacture a product. Anything that the customer is willing to pay for or an operation that changes the form, fit, or function of the part.