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Flashcards in 25 Lean Methods Deck (10)
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Kanban P.557

A system that signals the need to replenish stock or materials or to produce more of an item.


5S P.559

-Set (arrange)
-Shine (clean)


Poka-Yoke P. 560

Mistake-proof a process by building safeguards into the system that avoid or immediately find errors.


Continuous Flow Manufacturing (CFM) P.563

Method in which items are produced and moved from one processing step to the next at a time.


Single-minute exchange of die (SMED) P.564

-Identify and classify internal (machine down) and external activities (preparation/ followup)
-Make a video of the changeover process
-Separate internal and external activities
-Convert internal to external activities
-Apply engineering changes to convert any remaining internal activities to external activities as appropriate.
-Minimize external activity time


Heijunka (Production Leveling) P. 565

-Volume Leveling
-Product Leveling


Kaizen Event or Kaizen Blitz P.568

Small, intensive event or project over a relatively short duration, such as a week.

-The responsibility for implementation of changes as a result of the kaizen activity lies mostly within the team, and the risk of failure is small.
-Projects are time bounded and results must be demonstrated quickly.
-Projects are clearly defined.
-Improvement opportunities are readily identifiable, such as excess waste.


Kaizen P.569

An approach to process and enterprise management that recognizes the importance of each employee's creative ability and interest in continuous improvement.


Theory of constraints (TOC) P.570

A problem-solving methodology that focuses on the weakest link in a chain of processes.
1. Identify
2. Exploit (improve constraint)
3. Subordinate (adjust rate to match constraint)
4. Elevate
5. Repeat


Overall equipment effectiveness (OEE) P.573

OEE = Availability x Performance x Quality

Availability = Actual operation time / Planned production tim

Performance = (Total pieces / Actual operating time) / Ideal run time

Quality = Number of good pcs/ Total number of pcs