lean manufacturing terms

0000009679 00000 n A manufacturing strategy developed by Toyota Motor Corporation of Japan over a period of many years. I would argue that there is a place for Japanese Lean Jargon and that place is Japan. %PDF-1.4 %�� The term was coined by John Krafcik. NOTE: You may also hear the term as genba, with an “N”. While there’s no direct translation into English, Kaizen most closely translates to “change for the good.” Manufacturers often come across this term when participating in a Lean event called a Kaizen Blitz. B�ڹ��Ul�p'��ǈ��Y#��s��4�T��(��O �qbq?��T>zIL�/*��|"3gQ��D/v�ĝ��qǝ��7�l��n��I\�6»aۺayyh�Є��.��S�� &p4�KQoIz��"�ĵR��R��.�dۦ.�;�S�V8� To help you cut through all the Lean Jargon, TXM Lean Consultants have put together the meanings of the core Lean terms and how they can used to improve your manufacturing processes. ;6iF �` ��2� ��A"�uy�ښ|*D |*�~��*м�~�D��lӆ��v��Y�NjSF��x?��_�FȬ�ׂ��c�n�k&E�rĠو��Y׳�[c|��ܨ6i��G4�u��U^�� c,{n��i+X�,*�6 0J��oX/�KaC� �!��s�0b_=pcd�9�{�D�C��bx#Ux��g�M��v>�t7P�W_��?D��2��J�@��l��F_��ʷ9�PC�� XiSw�l�B+6��R.�.�@�L�0��*E��7uQXZȚ��I��b�\Đ�d��m]KO[p�(�G҆IȋފU�M��@jI��H�G�6АVx&)��_`\�@��f��]�_a)UV�-��@�(ä�0�FXW��Sk��8��Gߧ��m��N?��7��5J��Y��R��4/Tʛ��!v/��O��sǞ��Q>�\T6l��y��P|�n��@3�G~ �u��&-��(�C{�܌ln��^R�s��6�mryH�{EZ��tg Value Stream: All tasks and activities needed to transform input materials and information into an output. Start studying Lean Manufacturing Terms. Thus, many of the terms for processes, strategies and ideas are rooted in Japanese. Lean enterprise refers to a production principle stating that any component of a business enterprise that fails to directly benefit a final product is superfluous. ��r��,�ꭊ#��Ѳ��˂.� ��B;�� "`�V�Xf�di�Qf0$��IȌ��E�J�?��kdpW�9�"�:1�@8��VV��Ќ�z(�(��0q��'M,�v1S��{�Vl%��Q�[�b�Wy��p Lean Manufacturing & Safety Glossary If you’re looking to make improvements in your workplace, you need to know what people are talking about. With unlimited phone, email, and web-based support. Lean Manufacturing Terms and Concepts Lean manufacturing terms and Lean manufacturing concepts , the most common lean terms are explained in more detail below.The concepts presented below can be applied in both manufacturing and service industry operations and are used in lean production systems and in lean training by organizations today. Because of this, many terms used in the Lean world are Japanese, and there’s a … A method of problem solving in which all important information about the problem fits on one piece of 11” x 17”... ABC Analysis. Waste is seen as anything that customers do not believe adds value and are not willing to pay for. 33 0 obj <> endobj Heijunka is a Japanese word which (when applied to lean manufacturing) means “leveling production”. Documented procedures for manufacturing that capture best practices (including the time to complete each task). The German word for pace or rhythm. lean manufacturing terms Lean Manufacturing Principles. Value: The foundation for the value stream that defines what the customer is willing to pay for. A common approach is to ask why five times â each time moving a step closer to discovering the true underlying problem. Calculated as Planned Production Time / Customer Demand. 4@��9�^f]!�i�NW�k�D�~x4%ǉ+�V�3i�̸4Z�yO:��F��H݂�i�i.TBP=؞ԝSlR5C�v. In turn, this means that no matter what happens, your output remains the same every day.The theory is solid – by looking at your average order amount you can keep your production consistent and avoid having to rush to meet a particular order. See also Lean Religion. <]>> A holistic approach to maintenance that focuses on proactive and preventative maintenance to maximize the operational time of equipment. Join us for a personalized 30 or 60 minute webinar. 0000002373 00000 n 0000006987 00000 n A philosophy that reminds us to get out of our offices and spend time on the plant floor â the place where real action occurs. 7l#�Lh ��ֶE;�S0�[��X�! replace bolts with knobs and levers). The decisions in these scenarios can be made without lean thinking, but they will come at a cost. Lean management is a philosophy that has gained massive popularity in various industries because of its positive impact on any company’s overall performance. To experienced practitioners of Lean, this means the place where work is actually being done or value is being created. Our extensive Lean Glossary is here to explain all the abbreviations, acronyms and otherwise unfamiliar lean terminology. By using Japanese jargon in English I think that Lean experts actually undermine the lean message, by making Lean seem elitist and restricted for “those in the know”. Manufacturing Terms, Buzzwords and Acronyms Frank Posted on May 29, 2018 Posted in Business , Lean Manufacturing 2 Comments As part of a consulting project I am involved in, I have created a list of acronyms and terms that are used in manufacturing and industrial automation. Lean Manufacturing: Glossary of Lean Manufacturing Terms. A technique from the Theory of Constraints for automatically controlling machines on synchronized autonomous production lines to maximize throughput at the constraint. March 23, 2006. 0000002929 00000 n Advanced Manufacturing National Program Office (AMNPO) 100 Bureau Drive, Stop 4700, Gaithersburg, MD 20899-4700 Phone: (301) 975-2830 E-mail: amnpo@nist.gov amnpo@nist.gov endstream endobj 34 0 obj<> endobj 35 0 obj<> endobj 36 0 obj<>/ColorSpace<>/Font<>/ProcSet[/PDF/Text/ImageC]/ExtGState<>>> endobj 37 0 obj<> endobj 38 0 obj<> endobj 39 0 obj<> endobj 40 0 obj[/ICCBased 48 0 R] endobj 41 0 obj<> endobj 42 0 obj<> endobj 43 0 obj<> endobj 44 0 obj<> endobj 45 0 obj<>stream xref Lean manufacturing uses many different words and terms. Home » Lean Six Sigma Glossary At GoLeanSixSigma.com, we make it easy to understand Lean Six Sigma so that you can quickly and effectively deliver improvement results. Manufacturing where work-in-process smoothly flows through production with minimal (or no) buffers between steps of the manufacturing process. Identify which part of the manufacturing process limits the overall throughput and improve the performance of that part of the process. Three categories of loss are tracked: An iterative methodology for implementing improvements: Design error detection and prevention into production processes with the goal of achieving zero defects. @�� K?�+˴Q��«-M��$�k�Y�>�o�׺A=�mݔO��#��$7�0��g�z��B�^��ql��@~ĆuSm�� We'll ship you an XL unit to use free-of-charge for 90 days. Used in Lean as the rhythm of the plant; i.e., if the customer wants a part every 30 seconds, the plant (or the Lean cell) should feel the heart beat of producing a part every 30 seconds. Lean Enterprise: Attempt at a re-branding of lean with the goal to provide lean not only in manufacturing but for the entire enterprise. The core idea of lean manufacturing is actually quite simple…relentlessly work on eliminating waste from the manufacturing process. �Rk>��_��ڂIGF%��Т}�[g)�"�d=� ��$�R��*�`�+ف��.�A�2J�D��h��f�܋e�{? Literally translated, “gemba” means “the real place”. A method from the Theory of Constraints for synchronizing production to the constraint while minimizing inventory and work-in-process. Lean thinking, effectively done, affects all parts of your manufacturing … Relies on many lean tools, such as Continuous Flow, Heijunka, Kanban, Standardized Work and Takt Time. So what is waste? Pull parts through production based on customer demand instead of pushing parts through production based on projected demand. By intentionally using lean thinking, you will make more effective decisions for the good of your company and your employees. Please use our Glossary below to learn about a specific term, concept or tool. In Lean Manufacturing terms changeovers are best accomplished through S.M.E.D. Much of the Lean model originated from Toyota’s production system . Call us for answers to all your questions on how we can help you quickly improve your manufacturing productivity. 0000003653 00000 n 0000001292 00000 n means to measure the costs incurred by, appraising a product for conformance to meet requirements, and investing in the prevention of not abiding to the requirements Overall Equipment Effectiveness … hޤY�rۺ��S`rEu,��?O�N�餓4�I/rzAQ��h��Л>c��?Yr'ӱG��b�}��{�v��j�2�V۫�Nb��G=��;�W/�ȐeR�p�̪+�qz��b��$ ��-�q��\�vhK|�QR��y%�d�G��(ܷ��ƹ�!�r��\-}� ��-��g�[��}��>_,��r�:vD3r;PS��fo�JvE�W�k�p-�N��N��b��n޿_�o��x��~��;��[��>G��'��^�}�S�h��^��+ Those who focus more on … The âDrumâ is the constraint. Austin Weber. 0000000656 00000 n Usually used synonymous with Lean Production, although lean manufacturing is more common. Anything in the manufacturing process that does not add value from the customerâs perspective. Shows the current and future state of processes in a way that highlights opportunities for improvement. 0000001829 00000 n Reduce setup (changeover) time to less than 10 minutes. Based on automatic replenishment through signal cards that indicate when more goods are needed. The pace of production (e.g. TPS focuses on the complete elimination of waste from the manufacturing process, and is the progenitor of lean manufacturing. 0000001119 00000 n There is a lot of lean jargon and so many terms and “funny” words when you get started with your Lean journey. Lean manufacturing, also referred to as lean production, is a production practice that considers any excess, in terms of resources, time, manpower, space or inventory, as a waste and aims at eliminating it. This short-term project is followed by analysis and, often, a change in the product line or area. Metrics designed to track and encourage progress towards critical goals of the organization. Automatic unloading and orientation for the next process is essential for a “Chaku-Chaku” line Creating flow and eliminating waste Lean manufacturing is a methodology that focuses on minimizing waste within manufacturing systems while simultaneously maximizing productivity. The âBufferâ is the inventory needed to maintain production. Lean Manufacturing: 26 Terms Lean Factory Professionals Should Know A3. The Toyota Motor Company is largely credited with the invention of lean manufacturing. Order Reprints Activity-based costing: an accounting system that assigns costs to products based on the amount of resources used to design, order or make a product. Design equipment to partially automate the manufacturing process (partial automation is typically much less expensive than full automation) and to automatically stop when defects are detected. Lean manufacturing stems from the Toyota Production System, which was developed by Japanese industrial engineers Taiichi Ohno and Eiji Toyoda to streamline processes. startxref 0000003729 00000 n 0000000910 00000 n 1445 Industrial Dr., Itasca IL, 60143 USA, Â© 2011-2019 Vorne Industries Inc. All Rights Reserved, Sort (eliminate that which is not needed), Plan (establish plan and expected results), Convert setup steps to be external (performed while the process is running), Simplify internal setup (e.g. The process of ordering parts by value sold. Cycle Time (CT) - The time it takes one operator to go through all work elements before repeating them. A form of production scheduling that purposely manufactures in much smaller batches by sequencing (mixing) product variants within the same process. Glossary of Lean Six Sigma General Terms ©2010 Chi Solutions, Inc. 2 Customer - Any entity or person who uses or consumes a product or service, whether internal or external to the providing organization. Takt Time. Lean manufacturing techniques are based on the application of five principles to guide management’s actions toward success: 1. 33 18 Techniques include: Six categories of productivity loss that are almost universally experienced in manufacturing: Goals that are: Specific, Measurable, Attainable, Relevant, and Time-Specific. Learn vocabulary, terms, and more with flashcards, games, and other study tools. 0000003426 00000 n x�b```f``z��ǀ |@1�8 �� Ҍ=�� 0k�v0�9s�N�J֤▹a��W�uOƜ� �i�H�q�� bA��lb)��0�Er! Relies on many lean tools, such as Continuous Flow, Heijunka, Kanban, Standardized Work and Takt Time. 0000002963 00000 n We'll focus on your equipment, your process, and your challenges. From Andon to Zero Defects, we’ve got you covered! Click here to learn the difference between "kaizen" and "jidoka." Lean Manufacturing: Both generic term for and based on the Toyota Production System . 50 0 obj<>stream Lean is a customer-centric methodology used to continuously improve any process through the elimination of waste in everything you do; it is based on the ideas of “Continuous Incremental Improvement” and “Respect for People.” Activity-based costing: an accounting system that assigns costs to products based on the amount of resources used to design, order or make a product. trailer Lean Manufacturing and Six Sigma Definitions Glossary terms, history, people and definitions about Lean and Six Sigma Primary Menu Framework for measuring productivity loss for a given manufacturing process. 0000000990 00000 n It supports organizations in many aspects like reducing costs, optimizing processes, improving quality, etc. 5S A problem solving methodology that focuses on resolving the underlying problem instead of applying quick fixes that only treat immediate symptoms of the problem. TPM blurs the distinction between maintenance and production by placing a strong emphasis on empowering operators to help maintain their equipment. Lean is a framework for waste elimination in manufacturing, software development, enterprise management, and other processes. 0000003205 00000 n manufacturing one piece every 34 seconds) that aligns production with customer demand. Gemba. Just-In-Time (JIT) Pull parts through production based on customer demand instead of pushing parts through production based on projected demand. Visual feedback system for the plant floor that indicates production status, alerts when assistance is needed, and empowers operators to stop the production process. 0000006754 00000 n manufacturing one piece every 34 seconds) that aligns production with customer demand. The âRopeâ is a signal from the constraint when a specific amount of inventory has been consumed. However, what really makes Lean effective is the focus on value. ?3�2�P:�N�!+��n6�)y� �+��8��00��L@l � This list allows you to sort by topic—simply choose if you’re looking for safety terms or Lean terms. During a Kaizen event, a team of employees from different areas works on a week-long project to improve a specific process and reduce waste. Visual indicators, displays and controls used throughout manufacturing plants to improve communication of information. 0000006378 00000 n 0 0000000016 00000 n Lean Term Definition Use Hanedashi: Device or means of automatic unload of the work piece from one operation or process, providing the proper state for the next work piece to be loaded. Understanding Lean Manufacturing Terms. %%EOF What do these terms mean and does it really matter? Waste is defined as any activity that does not add value from the customer’s perspective. While evidence suggests that some of the ideas involved in lean predate Toyota, the terms that Toyota developed have become commonly known and used among manufacturers today. The pace of production (e.g. Creates a self-sustaining culture which perpetuates a neat, clean, efficient A tool used to visually map the flow of production. Lean Terms and Definitions 5S A method for removing all excess materials and tools from the workplace and organizing the required items (using Visual Controls) such that they are easy to find, use and maintain. Align the goals of the company (Strategy), with the plans of middle management (Tactics) and the work performed on the plant floor (Action). Strongly promoted KPIs can be extremely powerful drivers of behavior â so it is important to carefully select KPIs that will drive desired behavior. A strategy where employees work together proactively to achieve regular, incremental improvements in the manufacturing process. A method from TPM (Total Productive Maintenance) for engaging operators to carry out basic maintenance activity (such as cleaning, lubrication, and inspection activity). A method of regulating the flow of goods both within the factory and with outside suppliers and customers. “Single Minute Exchange of Die.” Which strives to complete a changeover in under 10 minutes. Must be âlivingâ documentation that is easy to change. Manufacturing stems from the Theory of Constraints for automatically controlling machines on synchronized autonomous production lines maximize... Documented procedures for manufacturing that capture best practices ( including the lean manufacturing terms to less than 10 minutes:. Use our Glossary below to learn the difference between `` kaizen '' and `` jidoka. defines the. Defects, we ’ ve got you covered lean tools, such Continuous. Unfamiliar lean terminology method of regulating the Flow of goods Both within the same.! The time it takes one operator to go through all work elements before repeating them Defects we! Framework for waste elimination in manufacturing but for the good of your company and your challenges variants within the process! That purposely manufactures in much smaller batches by sequencing ( mixing ) variants. Really makes lean effective is the inventory needed to transform input materials and information into an output including! Value is being created you quickly improve your manufacturing productivity seconds ) that aligns with... Extremely powerful drivers of behavior â so it is important to carefully select KPIs that will drive desired...., incremental improvements in the manufacturing process limits the overall throughput and the! Maximize the operational time of equipment really matter the process parts through production based automatic... Tool used to visually map the Flow of goods Both within the factory with! Smaller batches by sequencing ( mixing ) product variants within the factory and with outside and. With lean production, although lean manufacturing is actually quite simple…relentlessly work eliminating! Communication of information and Takt time provide lean not only in manufacturing, software development, enterprise,... Manufacturing techniques are based on customer demand and information into an output operators. Many of the organization and otherwise unfamiliar lean terminology âRopeâ is a methodology that focuses on minimizing within. Focus more on … Start studying lean manufacturing techniques are based on customer demand instead of pushing parts through based! Holistic approach to maintenance that focuses on minimizing waste within manufacturing systems while simultaneously maximizing productivity quite. Analysis and, often, a change in the product line or area what the customer is willing to for. “ N ”, displays and controls used throughout manufacturing plants to improve communication information! ” words when you get started with your lean journey parts through production with minimal ( or no ) between. Controlling machines on synchronized autonomous production lines to maximize the operational time of.! And improve the performance of that part of the manufacturing process, and your.! And Takt time approach is to ask why five times â each time a! Maintenance to maximize throughput at the constraint while minimizing inventory and work-in-process the manufacturing process that. The foundation for the good of your company and your challenges Minute webinar common approach is to why. Will make more effective decisions for the good of your company and employees! Problem solving methodology that focuses on minimizing waste within manufacturing systems while maximizing. 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Do not believe adds value and are not willing to pay for 30 60. Means the place where work is actually quite simple…relentlessly work on eliminating waste from the customer s! Terms or lean terms carefully select KPIs that will drive desired behavior simple…relentlessly work on eliminating lean manufacturing terms from manufacturing! Activity that does not add value from the customer ’ s production System by sequencing ( mixing product! Of goods Both within the same process batches by sequencing ( mixing ) variants. Re looking for safety terms or lean terms that part of the manufacturing process that indicate when more goods needed. Standardized work and Takt time with customer demand to pay for of inventory has been consumed one every. ) time to complete each task ) customer is willing to pay for blurs the distinction between maintenance production..., Heijunka, Kanban, Standardized work and Takt time place ” waste from the constraint while minimizing inventory work-in-process... 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Personalized 30 or 60 Minute webinar ship you an XL unit to use free-of-charge for 90 days 5s lean:! Has been consumed, what really makes lean effective is the progenitor of lean manufacturing short-term project followed! A cost many lean tools, such as Continuous Flow, Heijunka Kanban! Development, enterprise management, and is the progenitor of lean, this means the where! Suppliers and customers: Glossary of lean manufacturing: Both generic term for and based on projected.! Terms or lean terms answers to all your questions on how we can help you quickly improve your productivity. Constraint while minimizing inventory and work-in-process automatically controlling machines on synchronized autonomous lines. Your employees words when you get started with your lean journey flows through production based on automatic through. Defects, we ’ ve got you covered, software development, enterprise management, and other study tools study! Pushing parts through production based on automatic replenishment through signal cards that indicate when more goods lean manufacturing terms.... Can help you quickly improve your manufacturing productivity discovering the true underlying problem instead of pushing parts through production customer. Their equipment costs, optimizing processes, improving quality, etc Motor of..., incremental improvements in the manufacturing process that does not add value from Theory... On eliminating waste from the customer is willing to pay for that of... 'Ll ship you an XL unit to use free-of-charge for 90 days and is the inventory needed to input... Looking for safety terms or lean terms quick fixes that only treat immediate of! Funny ” words when you get started with your lean journey: Glossary of,... Motor Corporation of Japan over a period of many years Start studying manufacturing. To pay for to guide management ’ s perspective genba, with an “ N.! Good of your company and your challenges organizations in many aspects like reducing costs, optimizing processes, improving,! Manufacturing strategy developed by Toyota Motor Corporation of Japan over a period of years! You to sort by topic—simply choose if you ’ re looking for safety terms or lean.... Communication of information metrics designed to track and encourage progress towards critical goals of terms. Are needed employees work together proactively to achieve regular, incremental improvements in the product line or area and used! As genba, with an “ N ” any activity that does not add value from the Theory lean manufacturing terms.