Transcript Document

Glossary of Key Terms
Kenneth J. Andrews
EMP-5179-1-1
Glossary of Key Terms
• 5-S: A workplace organization methodology where emphasis is
placed on maximizing space and minimizing movement/travel
• Andon lights / boards: A visual control device in a production
area.
• Autonomation: automation with a human touch. Refers to semiautomatic processes where the operator and machine work
together. Autonomation allows man-machine separation. Also
referred to as Jidoka.
• Balanced plant: A plant where capacity of all resources are
balanced exactly with market demand.
• Balanced production: all operations or cells produce at the same
cycle time. In a balanced system, the cell cycle time is less than
takt time.
• Bottleneck: Any resource whose capacity is equal to, or less than
the demand placed on it.
Kenneth J. Andrews
EMP-5179-1-2
Glossary of Key Terms
• Capacity Constraint Resources (CCR): A situation is which a
series of non-bottlenecks, based on the sequence in which they
perform their jobs, can act as a constraint.
• Chaku – Chaku: A method of conducting single-piece flow, where
the operator proceeds from machine to machine, taking the part
from one machine and loading it into the next.
• Constraint: Anything that limits a system from achieving higher
performance, or throughput. It is also a bottleneck that most
severely limits the organization's ability to achieve higher
performance relative its purpose/goal.
• Error- proofing: designing a potential failure or cause of failure out
of a product or process.
• Evaporating Clouds: A problem of method used in Theory of
constraints. Same as Conflict Resolution
Kenneth J. Andrews
EMP-5179-1-3
Glossary of Key Terms
• External Setup (OED): Die setup procedures that can be
performed while machine is in motion. OED - "outer exchange of
die" (See Internal Setup).
• Flow manufacturing: a manufacturing methodology that pulls
items from suppliers through a synchronized manufacturing
process to the end product. The principle goal is faster response to
customer demand.
• Heijunka: Keeping total manufacturing volume as constant as
possible. [Same as Production Smoothing]
• Hoshin Kanri: A strategic planning approach that integrates the
practices of leadership with the practices of management.
• Information Management Task: The task of taking a specific
product from order-taking through detailed scheduling to delivery.
[See Value Stream].
Kenneth J. Andrews
EMP-5179-1-4
Glossary of Key Terms
• Internal Setup (IED): Die setup procedures that must be
performed while machine is in stopped. IED - "inner exchange of
die" (See External Setup).
• Jidoka: Stopping a line automatically when a defective part is
detected. [Same as Autonomation]
• Kaikaku: A radical improvement, usually applied only once within a
value stream. [Same as Flow Kaizen]
• Kaizen: Japanese term for incremental improvement. A team
approach to quickly tear down and rebuild a process layout to
function more efficiently.
• Kanban: techniques named after the Japanese word for card or
communication. Stocking technique using containers, cards and
electronic signals to make production systems respond to real
needs and not predictions and forecasts.
Kenneth J. Andrews
EMP-5179-1-5
Glossary of Key Terms
• Just-in-Time (JIT): manufacturing method where downstream
operations pull required parts needed from upstream operations at the
required time. Implementing JIT requires most features of lean
manufacturing.
• Lean: Producing the maximum sellable products or services at the
lowest operational cost, while optimizing inventory levels.
• Mistake-proofing: any change to an operation that helps the operator
reduce or eliminate mistakes.
• Muda: Anything that interrupts the flow of products and services
through the value stream and out to the customer is designated muda or waste.
• Nagara System: A production system where seemingly unrelated tasks
can be produced by the same operator simultaneously.
• One piece flow: Producing one unit at a time, as opposed to producing
in large lots.
Kenneth J. Andrews
EMP-5179-1-6
Glossary of Key Terms
• Pitch: The pace and flow of a product.
• Poka-Yoke: Techniques to mistake-proof a process.
• Policy Deployment: The selection of goals, projects to achieve the
goals, designation of people and resources for project completion, and
establishment of project metrics. (Same as Hoshin Kanri).
• Quality Function Deployment (QFD): Using a cross-functional team to
reach consensus that final engineering specification of a product are in
accord with the voice of the customer.
• Quick Changeover: The ability to change tooling and fixtures rapidly
(usually minutes), so multiple products can be run on the same
machine.
• Resource Activation: Using a resource regardless of whether
throughput is increased. (See Resource Utilization).
• Resource Utilization: Using a resource in a way that increases
throughput . (See Resource Activation).
Kenneth J. Andrews
EMP-5179-1-7
Glossary of Key Terms
• Right-Size: Matching tooling and equipment to the job and space
requirements of lean production.
• Sensei: An outside master or teacher that assists in implementing lean
practices.
• Shusa: The leader of the team whose job is to design and engineer a
new product and it into production.
• Single Minute Exchange of Dies (SMED): The reduction in die set-up
time. Set-up in a single minute is not required, but is used as a
reference.
• 6 Sigma: A structured process improvement program for achieving
virtually zero defects (3.4 parts per million) in manufacturing and
business processes.
• Standard operations: Clearly defined operations and standardized
steps for both workers and machines.
Kenneth J. Andrews
EMP-5179-1-8
Glossary of Key Terms
• Standard Work: Specifying tasks to the best way to get the job done in
the amount of time available while ensuring the job is done right the first
time, every time.
• Sub-Optimization: A condition where gains made in one activity are
offset by losses in another activity or activities, created by the same
actions creating gains in the first activity.
• Takt time: Takt is German for pace. Takt time defines the manufacturing
line speed and the cycle times for all manufacturing operations. Takt
time is computed as: Available work time per day / daily required
demand (parts/day).
• Theory of Constraints (TOC): A lean management philosophy that
stresses removal of constraints to increase throughput while decreasing
inventory and operating expenses.
• Value Analysis: Analyzing the value stream to identify value added and
non-value added activities.
Kenneth J. Andrews
EMP-5179-1-9
Glossary of Key Terms
• Value Stream: The set of specific actions required to bring a specific
product through three critical management tasks of any business:
Problem-solving, Information management and physical transformation.
• Value Stream Mapping: A process to determine the value added to a
product as it goes through a manufacturing process.
• Visual Controls: Displaying the status of an activity so every employee
can see it and take appropriate action.
• Waste: Anything that uses resources, but does not add real value to the
product or service.
Kenneth J. Andrews
EMP-5179-1-10