Key Terms and Definitions Flashcards
What is LSS?
LSS is a business strategy of creating and sustaining value for the customer by identifying value streams and eliminating waste.
3 Benefits of LSS
1) Improve Quality
2) Reduce Costs
3) Save Time (Reduce Leadtime)
LSS Key to Success
Buy in from everyone.
Who Developed Lean
- Toyota (real name Toyoda)
- Also know as Toyota Production System (TPS)
- Taiichi Ohno: Father of Lean
When Was Lean Created / Popular
- Created: Post WWII
- Popular: mid 90’s
Who Developed Six Sigma
- Motorola
- Bill Smith
- SPC applied to quality
When Was Six Sigma Created / Popular
- Created: Mid-80s
- Popular: GE; Jack Welch; Created Belt Colors
What did Vilfredo Pareto Introduce?
- Pareto Chart
- 80/20 Principle
- 20% of the effort = 80% of the results
- 20% of the causes = 80% of the effects
- Focus on the significant few vs instead of the insignificant many
What did Henry Ford Introduce?
The assembly line.
What did Walter Shewhart Introduce?
Special cause and common cause variation
- Special cause: abnormal
- Common cause: explainable
Developed Plan-Do-Check-Act (PDCA) method of problem solving.
What did Fredrick Taylor Introduce?
There’s one best way to do it
- standardized processes
What did W. Edward Deming Introduce?
Went to Japan and introduced:
Total Quality Management
- SOPs: standard operating procedures
- SPC
- Control Charts
Considered: Father of Quality
“Quality is everyone’s responsibility.”
What did Dr. Kaora Ishikawa Introduce?
Fishbone Diagram
- Also known as Cause and Effect Diagram
Diagram Design
- Head of Fish: Ultimate Problem
- Typically 6 Bones: Manpower, Material, Machine,
Method, Measurement, Management
- Start a the End of each fishbone (current state) and
work towards the spine
- Ask WHY until no longer can to reach root cause
- Ask THEREFORE, working back towards the outer
portion of the bone
What did Shigeo Shingo Introduce?
Poka-Yoke
- mistake proofing
- preventing an error from occurring
Soft = message only Hard = will prevent from occurring
What did Taiichi Ohno Introduce?
Muda
- 7 types of waste +1
- waste = non-value added steps in process
T = Transportation I = Inventory (excessive hides problems or defect) M = Motion W = Waiting O = Over Production O = Over Processing (unnecessary processing) D = Defects \+1 = Unused Employee Creativity
What is the Toyota House of Quality?
Foundation (Stability)
- Heijunka (leveling of production)
- Standardized Work
- Kaizen
Pillars
- Left: Jidoka (stop the line; automation with a human touch)
- Right: JIT
Roof
- I = Improved Quality
- R = Reduced Costs
- S = Saves Time (reduce leadtime)
What is the Toyota Way House?
Pillars
- Left: Continuous Improvement
- Right: Respect for People
What is Value?
Customer determines value
What is value added for goods?
Something that changes the shape or form of a product that the customer is willing to pay for
What is a Value Stream for Goods?
From the time the customer places order until the time the customer received the product..
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How is Value Achieved?
Done across processes (cross functionally) instead of done by a department (functionally)
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What are the 3 levels of value streams from start to stop?
1) Process
2) Door to Door (factory / get to until leave hospital
3) Enterprise (getting sick until complete recovery)
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What is process mapping?
- Showing from process to process.
- Also known as flowcharting.
- Uses symbols and decisions
What is value stream mapping?
Articulates the flow of material and information into and out of processes.
What are the benefits of value stream mapping?
Benefits:
1) (Gemba) Seeing where the work happens
2) Quickly identifies waste
3) Understanding materials and information flow
What are the 2 types?
1) Current state
2) Future state
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How is value stream mapping done?
- Involves everyone
- If possible, organize chronologically
1) Start with start / stop points
2) Add process boxes
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What is the order value stream mapping is done?
1) Processes
- stated in verb and nouns
2) Connectors
- Arrows between boxes
- Either push or pull arrows
3) Symbols
- See handout
4) Data Boxes
5) VA / NVA time
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What is a data box?
Box to illustrate and show data relevant to the process of a value stream
Contains
- Time:
- Processing, wait, cycle
- Quality
- Number or % of defects or rejects
- Inventory
- How much? Costs/Expenses, Revenue
- Resources
- # of people
- space
- distance traveled
- Yield: how many
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What is change over time?
Period of time to prepare a device, machine, process or system to change from producing the last good piece of the last batch to processing the first good piece of the new batch.
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What is SMED?
Single minute exchange of die
What is TAT?
Turn around time
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What is Takt time?
available time / customer demand
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How to improve Takt time?
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What is Kaizen?
Kai (change) zen (good)
continuous improvement
Process improvement Function
f(x) = y + E
f = Process x = Input y = Output E = Error
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What are the types of waste?
- Muda
- Muri
- Mura
What is Muda?
Muda
- 7 types of waste +1
- waste = non-value added steps in process
T = Transportation I = Inventory (excessive hides problems or defect) M = Motion W = Waiting O = Over Production O = Over Processing (unnecessary processing) D = Defects \+1 = Unused Employee Creativity
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What is Muri?
Overburdening a person or machine
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What is Mura?
Unevenness in the work-flow
- Can be caused by batch processing
- Improve using Heijunka (leveling)
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What is Heijunka?
Leveling
- maintaining a static work-load avoiding dramatic
shifts or swings in production - Level: start at the beginning of the value stream (the first process?)
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How is Heijunka improved?
- One piece flow processing instead of batch and que
processing - Push vs Pull
- FIFO
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What is batch processing?
-Dedicated work stations designed for a specific work function - comparison is an elevator
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What is One Piece Flow?
- completing the production or service from start to finish with as little inventory as possible between tasks (steps)
- a collection of work cells
- comparison is an escalator
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What is push?
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What is pull?
- Create pull by starting at the end of the value stream
- Identify and eliminate constraint (bottleneck). Move upstream, to the next constraint and eliminate…
- This is kaizen; establishing a standard and improving through kaizen event, establish new standard
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What is FIFO?
- First in first out
- introduce FIFO at the beginning of the value stream
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FIFO and XOXO
X = heavy workload O = light workload
Mix XO to Heijunka (creates leveling)
FIFO avoids?
- Obsolescence
- Poor customer satisfaction
- Aging material
- Decay-
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What is 5S?
1) Sort
2) Straighten
3) Shine
4) Standardize
5) Sustain
What is sort?
Clearly distinguish needed items from unneeded and eliminate the latter
What is straighten?
Keep needed items in the correct place to allow for easy and immediate retrieval
What is shine?
Keep the workplace neat and clean
What is standardize?
The method by which sort, straighten and shine are made habitual
What is sustain?
Maintain established procedures
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Why do / benefits of 5s?
Safety, Reduce Waste and Clutter
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What are ergonomics?
Fitting the workplace for the people
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What is motion economy?
Seeks to eliminate, combine, reduce and smooth motion
- Considers the workplace arrangement
- Placement of tools, supplies, and equipment to
minimize motion
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Why standards / standardization?
Necessary for:
- reduce variation
- Training
- Auditing
- Improvement
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Why auditing
Accountability
- Kamishibai = audit board
- Process Metric
- Outcome Metric
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Taiichi Ohno - Standards
Without standards, continuous improvement isn’t possible.
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How to document SOPs
Time, Materials, Work Sequence
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What is work sequencing?
Individual work steps; usually only consists of a verb and noun
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What is the process for a kaizen or a rapid improvement event?
Create standard then kaizen (continuous improvement)…establish new standard then kaizen…
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What is TWI?
Training within industry
- Methodology developed during WWII
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What’s JIT and how does it work?
JIT = Just in Time
- materials when needed; in the quantities needed
- Based upon pull systems of production determined
by customer - Requires production scheduling based on the needs
of the customer - Supplies delivered only when needed
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What’s a Kanban?
Kanban is used to signal low levels of inventory
- Signal of some kind: Sign, signboard, doorplate,
poster, billboard, card
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Why visual management?
- Manage what you want to make visual
- Don’t have to communicate verbally
Example: Andon Light
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What is Jidoka?
- Automation with a human touch
- Stop when something goes wrong
example: Andon Light
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Zero Defects are Possible
- Never accept a defect
- Never create a defect
- Never pass a defect
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What’s Poka-Yoke?
Poka (mistake) - Yoke (proofing)
- preventing an error from occurring
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What are the types of Poka-Yoke?
Soft: visual only
Hard: will prevent from occurring
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Tools to identify root cause
- 5 why
- Pareto Chart
- Cause and effect (Fishbone)
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What is a problem?
Deviation from standard
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Lean problem solving methodology
Plan-Do-Check-Act (PDCA)
PDCA - Benefits / Drawbacks
Benefits: quick
Drawbacks: less scientific
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Six Sigma problem solving methodology
Define-Measure-Analyze-Improve-Control (DMAIC)
DMAIC - Benefits / Drawbacks
Benefits: scientific
Drawbacks: takes longer
What’s an A3?
A size of a piece of paper (about a legal size)
- Toyota uses for problem solving
- Information all on one side of paper
- Left side what
- Right side how
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What are SMART goals?
S = Specific M = Measurable A = Agreed to R = Realistic T = Time bound
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What is Gemba?
The place where the value is created
- where the working is occurring (shop floor) and value is added
Purpose of Gemba?
- Go see
- Ask why
- Show respect
What is Genchi Genbutsa?
- Personal involvement
- Learn by doing
