Key Terms and Definitions Flashcards
1
Q
What is LSS?
A
LSS is a business strategy of creating and sustaining value for the customer by identifying value streams and eliminating waste.
2
Q
3 Benefits of LSS
A
1) Improve Quality
2) Reduce Costs
3) Save Time (Reduce Leadtime)
3
Q
LSS Key to Success
A
Buy in from everyone.
4
Q
Who Developed Lean
A
- Toyota (real name Toyoda)
- Also know as Toyota Production System (TPS)
- Taiichi Ohno: Father of Lean
5
Q
When Was Lean Created / Popular
A
- Created: Post WWII
- Popular: mid 90’s
6
Q
Who Developed Six Sigma
A
- Motorola
- Bill Smith
- SPC applied to quality
7
Q
When Was Six Sigma Created / Popular
A
- Created: Mid-80s
- Popular: GE; Jack Welch; Created Belt Colors
8
Q
What did Vilfredo Pareto Introduce?
A
- 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
9
Q
What did Henry Ford Introduce?
A
The assembly line.
10
Q
What did Walter Shewhart Introduce?
A
Special cause and common cause variation
- Special cause: abnormal
- Common cause: explainable
Developed Plan-Do-Check-Act (PDCA) method of problem solving.
11
Q
What did Fredrick Taylor Introduce?
A
There’s one best way to do it
- standardized processes
12
Q
What did W. Edward Deming Introduce?
A
Went to Japan and introduced:
Total Quality Management
- SOPs: standard operating procedures
- SPC
- Control Charts
Considered: Father of Quality
“Quality is everyone’s responsibility.”
13
Q
What did Dr. Kaora Ishikawa Introduce?
A
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
14
Q
What did Shigeo Shingo Introduce?
A
Poka-Yoke
- mistake proofing
- preventing an error from occurring
Soft = message only Hard = will prevent from occurring
15
Q
What did Taiichi Ohno Introduce?
A
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
16
Q
What is the Toyota House of Quality?
A
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)
17
Q
What is the Toyota Way House?
A
Pillars
- Left: Continuous Improvement
- Right: Respect for People
18
Q
What is Value?
A
Customer determines value
19
Q
What is value added for goods?
A
Something that changes the shape or form of a product that the customer is willing to pay for
20
Q
What is a Value Stream for Goods?
A
From the time the customer places order until the time the customer received the product..
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A
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22
Q
How is Value Achieved?
A
Done across processes (cross functionally) instead of done by a department (functionally)
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A
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24
Q
What are the 3 levels of value streams from start to stop?
A
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
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What is value stream mapping?
Articulates the flow of material and information into and out of processes.
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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
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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
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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
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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
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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)
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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
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What is sort?
Clearly distinguish needed items from unneeded and eliminate the latter
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What is straighten?
Keep needed items in the correct place to allow for easy and immediate retrieval
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What is shine?
Keep the workplace neat and clean
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What is standardize?
The method by which sort, straighten and shine are made habitual
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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)
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PDCA - Benefits / Drawbacks
Benefits: quick
Drawbacks: less scientific
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Six Sigma problem solving methodology
Define-Measure-Analyze-Improve-Control (DMAIC)
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DMAIC - Benefits / Drawbacks
Benefits: scientific
Drawbacks: takes longer
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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
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Purpose of Gemba?
- Go see
- Ask why
- Show respect
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What is Genchi Genbutsa?
- Personal involvement
| - Learn by doing
