LEAN TERMINOLIGY
Andon
A visual management tool that highlights the status of operations in an area at a single glance and that signals whenever an abnormality occurs.
Continuous Flow
Producing and moving one item at a time (or a small and consistent batch of items) through a series of processing steps as continuously as possible.
Cycle Time
The actual time it takes to complete a series of tasks(Standard Work Sequence), as timed by observation (Measured with a stopwatch).
Daily Management
is an approach to running an organization that supports the concept of daily continuous improvement, an approach to work that systematically seeks to achieve small, incremental changes in processes in order to improve efficiency and quality.
4 M’s
The variables that a production system manipulates to produce value for customers (Manpower, Material, Machine, Method).
5S
One of the fundamental tools in Lean, it entails creating an organized, effective workspace that supports the processes being performed in the area. The 5S’s are described as follows: Sort, Straighten, Scrub, Standardize, Sustain.
Gemba
The Japanese term for “actual place”, often used for the shop floor or any place where value-creating work actually occurs.
Jidoka
Providing machines and operators the ability to detect when an abnormal condition has occurred and immediately stop work. This builds in quality and enables the separation of operator and machine.
Just-In-Time (JIT)
A production system that makes and delivers just what is needed, just when it is needed, where it is needed, and just the amount needed.
Kaizen
“Continuous Improvement” of an entire value stream or an individual process to create more value with less waste.
Kanban
A signaling device that gives authorization and instructions for the production, transportation, withdrawal, or replenishment of items in a pull system.
Lead Time
The time required for a product to move through a series of processes from start to finish.
Lean Promotions Office (LPO)
A resource team for a lean transformation. They provides value stream managers with technical assistance , such as: Training, Workshops, and Progress Measurement.
Muda (waste)
Any activity that consumes resources without creating value for the customer.
Ohno, Taiichi
Toyota executive widely credited as the chief architect of the Toyota Production System (TPS).
Overproduction
Producing more, sooner or faster than is required by the next process. The worst waste.
Poke - Yoke
Mistake proofing device or procedure to prevent a defect during order taking and manufacture.
Pull Production
A method of production control in which downstream activities signal their requirements to upstream activities.
Push Production
Processing large batches of items at a maximum rate, based on forecasted demand, then moving them to the next process, regardless of the actual requirements of the next process.
Root Cause Problem Solving
In lean problem solving takes place using a structured method that follows the PDCA cycle.
Sensei
Japanese term for “teacher”.
Standard Work
Precise procedures for each operator’s work in a production process, based on three elements: Takt Time, Standard Work Sequence, and Standard Work In Process.
Standard Work In Process (SWIP)
The amount of inventory needed before each step in a process to keep the process moving smoothly.
Takt Time
The available production time divided by customer demand. The purpose of takt time is to precisely match production to demand.
Value Stream Map
A simple diagram of every step involved in the material and information flows needed to bring a product from order to delivery.
Visual Management
The concept of making a workplace more effective by making the current condition of a workplace obvious at a glance.
Waste Elimination
One of Lean’s fundamental elements it is often described by one of seven categories: over-production, waiting, conveyance, waiting, over-processing, inventory, motion, and correction.
Waterstrider
A team member who collects and delivers parts, tools, and supplies to multiple processes on a just-in-time basis to Takt Time.