Yellow Belt Flashcards
Lean concepts
To eliminate waste in any process
What is Muda?
Japanese word for waste.
Useless or unnecessary.
Non value added (NVA) task in a process.
The seven Muda
Overproduction
Correction
Inventory
Motion
Conveyance
Over-processing
Waiting
Muda of over production
Easiest form of Muda to spot
A product, part, or service was produced too fast either at the wrong time or in too much quantity.
Muda of Correction
Muda of rework
When rework occurs ,overall production time increases, additional labor and material is used.
Poka yoke
To make it more difficult to create defects than to not create defects during a process
Muda of inventory
Items purchased or created before they are needed in a manufacturing process
Muda of motion
How employees move in a process
Relevant to people powered process
Muda of conveyances
Movement of outputs, products, or resources
Muda of Over processing
Ignorance
Desire of perfection
Or excitement
Lack of training for efficiency
Muda of Waiting
Idle time in process
When processes are not coordinated properly
Correction in scheduling or balancing people and production is key to solve it
Other forms of waste
Taiichi ohno agreed on other types of wastes as well
Talent
Ideas
Capital/cash
Type I Muda
Non value added tasks that might actually be essential
E.g inspection of products
Auxiliary processes such as hr processes
Type II Muda
Non value added tasks that are not essential explained in 7 types of Muda
5S
Japanese lean approach to organize work space and make it more effective and efficient.
Sort (Seiri)
Straighten (Seiton)
Shine (Seiso)
Standardize (Seiketsu)
Sustain (Shitsuke)
Sort ( Seiri)
To take inventory and get rid of unnecessary items and identify unused or wasted
resources
Make room or reorganization
Straighten (seiton)
Streamlined arrangement of workspace
Every tool must be given a home
Location of resources must be labeled clearly
Visual control and common sense operation
Shine (Seiso)
Keep workplace neat and clean
Physically and digitally
Standardize ( Seiketsu)
Maintain all progress achieved
Sustain (shitsuke)
Everyone in the organization has to be aware of the standards and keep up with them on daily basis
Benefits of 5S
Reduced risks of accidents & safety issues
Increased compliance with regulations from organization
Foundation that makes additional improvements easier
Waste is easier to identify and eliminate
Production and quality are generally improved
Just in time manufacturing
Lean concept originated in Toyota
Manufacturing just the right quantity required for the next process
