Yellow Belt Chapter 4: Lean Concepts Flashcards
The Seven Muda
Lean concepts are based on muda which are things that waste labor, time, and resources causing money.
7 muda/wastes:
overproduction, correction, inventory, motion, conveyance, over-processing, waiting
(COIM-COW)
Overproduction (single unit-for a product)
Overproduction-
a product or service that was produced too fast, too much of a product, or @ wrong time.
Correction
Correction-
when a defect exists and that causes the defect to be resent to be correctly produced; causes waste in labor and extra cost.
Inventory (refers to overproduction of whole product)
Inventory- muda referring to the build up of final products that are made at wrong time, too fast, or too many.
Motion
Motion- repetitive and unnecessary actions that cause problems with double-entry
ex: use sphagetti diagrams
Conveyance
Conveyance- similar to motion muda but particular to outputs, products, or resources
Over-Processing
Over-processing muda-
when more resources (time, labor, money) are put into a product than it is required.
Waiting
waiting muda-
caused when there is an excess in time wasted from one process to another.
***caused by non-coordinated processing steps
Other Forms of Waste
Talent
Ideas
Capital/Cash
Talent
Talent Muda- hiring the wrong person for the job who has more talent in other more advanced areas that are not being used.
Ideas
Ideas muda- when thoughts and ideas of people are discounted
Capital/Cash
capital/cash muda-
not properly using the capital to create more cash flow
The Two Types of Muda
Type I Muda-
* Type I muda are a category of muda that results from the creation of necessary checkpoints and quality measures for a product to protect from product defects.
Type II Muda-
The regular types of muda defined above in (COIM-COW and TIC).
No use to management!
5S (Phase 1: Sort)
Sort Phase- you will remove all unnecessary items from process and keep all necessary items in the process.
5S (Phase 2: Straighten)
After you sort, you must straighten. Each Value-Adding item is given a home to streamline the process with tape or numbers to designate the items.
5S (Phase 3: Shine)
After straightening, you must shine the item.
-Shine process means that you will keep the process clean and neat. Please put all equipment where it belongs from “straighten phase.”
5S (Phase 4: Standardize)
Standardize means to create an “understood protocol” for everyone to follow. These steps will be followed accordingly:
- “Sort, Straighten, Shine”
5S (Phase 5: Sustain)
Sustain:
If we use 5S, we must sustain it. Everyone must sustain the organizations 5S design.
Just-In-Time Manufacturing
JIT shorthand; meaning thst each process is synchronized with another process. These processes are combined together working perfectly.
Also, can refer to meeting customers demands when required to.
Lean Concepts that crop up in many improvement methodologies
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