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Lean Manufacturing Implementation

The Lean Manufacturing Glossary

Change Agent: Someone who will lead the company from the traditional manufacturing mentality to becoming a Lean organization. This person may come from within or outside the company.

Error Proofing: (Japanese Poka-Yoke) Also called Mistake Proofing. A system that addresses both the product and the processes to detect errors before they become defects.

Five S's: A method of workplace organization and visual controls developed by Hiroyuki Hirano.

Japanese "S" American "S"
Seiri (Organization)
Seiton (Tidiness)
Seiso (Purity)
Seiketso (Cleanliness)
Shitsuke (Discipline)
Sort
Set in Order
Shine
Standardize
Sustain

Inventory Turns: How many times you can "Turn" your money over in a year. This is expressed as a ratio of the total inventory to the annual sales. Example: If the dollar value of the inventory (a number that probably must be reported to both your banker and the government) is $5,000,000 and the annual sales is $25,000,000 the inventory turns is five. If the inventory can be reduced to $1,000,000 the inventory turns become 25. Increasing your inventory turns may require a paradigm shift by your banker who may think inventory is something of value rather than MUDA.

Just-In-Time (JIT): Producing the product at the correct time in the correct amount, to meet the customer's requirements - No More; No Less. The opposite of Just-In-Time is "Just-In-Case"; avoid this temptation.

Kaizen: The Japanese word for continuous improvement to eliminate waste. As the name implies, with continuous improvement you are never done; even the improvement can be improved.

Lead Time: The time that is required from receipt of order until shipped to the customer.

MUDA: The Japanese word for waste or any activity that does not add value to the customer.

One-Piece Flow: Moving the product through each operation (both in manufacturing and in the office) as a single part, never handled in batches.

Operator/Machine Balance Charts: A systemic method of measuring the work being done within the cycle time of the operation. The work is then divided into:

  • Value Added Time
  • Incidental Work
  • Waste (MUDA)

Then a conscious effort is made to eliminate the waste and reduce incidental work.

PPM: Parts per million. The number of defective parts the customer receives per million parts shipped. This can be used to measure your supplies as well as your customer use, to measure you.

Paradigm Shift: Changing one's concept as what was believed to be correct. For example:

A production machine must be kept running all the time.
to
It's ok for a production machine to be idle, but not ok for an operator to be idle.

Waste is scrap and rework
to
Waste is anything that doesn't add value to the product or Waste is anything for which the customer is not willing to pay.

Poka-Yoke: Also called Error Proofing, Mistake Proofing or Zero Quality Control (ZQC). Poka- Yoke is a system and/or a device that prevents errors before they become defects. With Poka-Yoke operators are not blamed for the errors, but instead find ways to keep errors from becoming defects. When used with other Lean Principles Poka-Yoke can be a very valuable tool in the overall Lean Manufacturing process.

Production: Skilled: The ratio of the number of production operators to the number of skilled trades personnel.

Sensei: The Japanese word for teacher. In acquiring Lean Knowledge the Sensei often is personally involved with the student.

TAKT: The German word for Pace or Rhythm. Used in Lean as the rhythm of the plant. ie-If the customer wants a part every 30 seconds, the plant (or the Lean Cell) should feel the heart beat of producing a part every 30 seconds.

TAKT Time: Total available production time divided by the customer & requirement. Note: Include all planned activities such as clean-up, safety meetings, etc.

Example

(1) 8 Hour Shift=480 Minutes-(2) 10 Minute Breaks=460
------------------------------------------------------
1840 Pieces/Day Customer Requirements

TAKT Time = .25 minute or 15 seconds

Traditional Manufacturing: (Mass Production) Grouping like processes together (paint, welding fabrication, etc.) and then making large batches of a part and holding them in queue waiting for the next process. Also called "Batch and Queue."

Value Stream Mapping: A systematic method to identify all the activities (door-to-door) required to produce a product or product family. The "Map" will inclide both the flow of the material and the flow of information. It should first be used to describe the current state and then redone to depict the future state.



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