Module 8 Section B Continuous Improvement Starting with Topic 6

Special (assignable) Cause

A _____ of variation, on the other hand, leads to changes in the process that can be traced to a specific root cause and so can and should be alleviated as soon as possible. If _____ variation is present, the process output may suddenly move from conformance to nonconformance. Sporadic quality problems are due to ____ of variation.If a process has shifted from its statistical mean, it is a good sign that there will be an ___ such as a worn part or a miscalibrated instrument.

Variation

A change in data, a characteristic, or a function that is caused by one of four factors: special causes, common causes, tampering, or structural ____. ____ can affect product dimensions, characteristics, functions, or data. For example, in a continuous improvement environment, actual run hours can be compared to standard run hours to determine the degree of _____. For process management, the ___ must be tracked back to its sources. The degree of ____ can be insignificant, or it can be so great that it results in nonconformance. The Dictionary defines two main causes of ___: Common Causes (random causes) and Special Causes (assignable causes)

A3 x3 A3 Report x2 A3 x rest

A good ___ process reflects a solid understanding of the situation and a mastery of core lean tools and thinking. ____ thinking is thinking about how to express a problem and a solution in the form of a short story that is easy to digest. ____ thinking fosters learning and becomes a basis for collaboration. It is standardized storytelling. An ___ is a one-page story on a large sheet of paper. Both the results of the problem identification and the planning are presented in a concise report. There are four kinds of _____ 1. Hoshin planning ____—used to summarize department and company hoshins for strategic planning (Hoshin means statement of objectives in Japanese.) 2. Problem-solving ______—used to summarize problems and countermeasures 3. Proposal _____—used to present new ideas 4. Current status _______—used to summarize the current condition of a hoshin, problem, or concern

Model

A representation of a process or system that attempts to relate the most important variables in the system in such a way that analysis of the ____ leads to insights into the system. Frequently, the ____ is used to anticipate the result of a particular strategy in the real system.

Special Causes (assignable causes)

A source of variation in a process that can be isolated, especially when its significantly larger magnitude or different origin readily distinguishes it.

Takt Time

A synchronous pull system controls the velocity of flow through processes by using ______. This results in an overall reduction of lead time. This requires knowing and standardizing operation times, which will enable completion of an assembly produced at one workstation that will in turn trigger production of an assembly at the upstream workstation throughout the production process. It also assumes that, through process improvements, organizations can implement batch sizes that are consistent with the desired rate of flow. The trigger can be recognized by material requirements planning application software, which can then indicate the need to start the replacement for the assembly just pulled.

Indicator Signal Control Guarantee

A visual system consists of visual devices that share information, give instructions, or limit actions. Visual ______: Gives information, such as the location of a tool Visual ____: Tells you that an action is necessary, such as a kanban signal or a signal on a board that a linked workstation needs assistance or the line will have to stop Visual _____: Limits behavior, such as a square painted on the floor to indicate where a bin of parts should be placed _______: Allows a correct response only

Supermarket Approach

A way of managing inventory and improving picking by making all parts easy to take off of a shelf, much like the shelves of a supermarket. Inventory is then restocked in such a way that employees always have easy access.

P-chart

Another type of control chart is a _____, which is a percentage chart that can be used to show percentages of sample averages exhibiting a given characteristic as tracked over time. If the same data were used, a _____ would closely resemble the corresponding x bar chart, but, rather than a numeric scale, it would display a percentage variation from the mean on the side and the upper and lower control limits would be translated into equivalent percentages. One key benefit of using a _____ is that the sample size can vary between samples but the resulting percentages will take this into account and still be comparable.

Out of Control

Below are four examples of Nelson's eight tests for special causes: 1. One point beyond zone A (3 sigmas) (outside of the UCL or LCL) 2. Nine or more points in a row above the mean (or nine plus below the mean) 3. Six points in a row steadily increasing or decreasing 4. two out of three points in a row in zone B (2 sigmas) or beyond in the same direction 5. four out of five points in a row are more than 1 standard deviation from the mean in the same direction (shift or trend) If these or the other three of these tests (not shown) are true, the process would probably be considered to be _____

Automated Manufacturing Design

Benefits of ______ tools include: 1. Increased production productivity 2. Increased efficiency 3. Improved product quality.

Benchmark Measures SCOR Model (Supply Chain Operations Reference Model)

By identifying "best in industry" performance, operations can focus on improving key activities by setting _____: a set of measurements (or metrics) that is used to establish goals for improvements in processes, functions, products, and so on. _____ are often derived from other firms that display best-in-class achievement. An example of a benchmarking framework is the _______ It defines key operations metrics (e.g., perfect order fulfillment) so that organizations can compare their processes or results against appropriate industry standards or competitors.

Scrub

Clean and inspect the work area. Keep everything, every day, swept and clean. Why is it important? Turn the workplace into a clean, bright place where everyone will enjoy working. Keep things in a condition so they are ready to be used when needed. Examples: Cleaning Log

Visual Management

Collaboration and the use of ____are principles of lean manufacturing that have been widely adopted in many manufacturing environments. _____ techniques include: 1. Visual Workplace 2. Visual Management triangle 3. Clean workplace 4. Visual System 5. Visual Communication 6. Visual workplace reporting

Benchmarking

Comparing products, processes, and services to those of another organization thought to have superior performance. The target may or may not be a competitor or even in the same industry. It can be used at different levels, from organizational strategy, to business processes and tactics, to operations. ____ can be performed internally (against a similar process within the organization) or externally (against comparable organizations). These external organizations may or may not be direct competitors. They could, for example, be in the same industry but in different geographical markets.

Process Variation

Controlling ______ is the primary method of ensuring that manufacturing or service processes remain in conformance with specifications, which ultimately results in efficient and effective operations and control over operational costs. Organizations need to measure and control their processes before looking elsewhere for ways to improve profitability and quality.

Standardize

Create standards for performing the above three activities. Why is it important? Ensuring that conditions do not deteriorate to the former state facilitates implementation of the first three pillars. Examples: Standardize processes: standard operating procedures. Document these standards on visual displays so that the workers can easily see them.

Sustain

Ensure that the standards are regularly applied. Instill discipline to avoid backsliding. Why is it important? The consequences of not keeping to the course of action are that the improvement process was a waste. Examples: Explaining benefits of the change. Enforcing consequences. Periodic audits.

Worker Efficiency

From the standpoint of ____, the tool and equipment layout techniques include: 1. Minimizing wasted effort in tool use by locating tools in well-marked and accessible locations 2. Making tools most frequently in use the fastest to access 3. Accounting for the ergonomic impact of lifting and moving materials and equipment and the needs of workers of different physical traits.

Kit

Further back up the value chain, connectivity can provide faster and better information to ___ assemblers and on the types of ____ to assemble. A_____ is components of a parent item that have been pulled from stock and readied for movement to a production area.

WIP Lead Time

Goals in lean production include reducing _______ and _______ by: 1. Producing only what is needed to meet (and not exceed) customer demand and to limit WIP to what is needed to support the continuous flow of product to the customer (the takt time). 2. Capping the amount of finished goods at what is required to meet demand after accounting for cycle time (shifting production from one product to another), transportation time, safety stock, seasonality, and promotions. This will reduce the amount of WIP in the system and allow continuous improvement activities to take place. 3. Improving the flexibility of the system and decreasing time for changeovers. This requires efficient process layouts, cross-trained employees, and flexible technology.

In Control

If the process is ____, the sample average will be within the set limits (assuming a normal distribution centered at the central line). If special causes are present, they will be detected, because they typically cause one or more data points to fall outside or very close to the limits or to show other trends.

Pull System

In a _____, demand is matched to supply. The factory produces only what its customers use. Each workstation produces only enough to supply what the next workstation in the process requires. In other words, a workstation makes only enough to replenish what the next workstation in the process has used. Parts inventory may be managed with a supermarket approach

R-Chart

In an _____: the range of variation within the set of samples for a given data point is calculated as the highest reading minus the lowest reading. This chart is therefore a measure of the degree of variability in samples. The UCL for the sample ranges is calculated and placed on the ____ to show when there is too much variation in the samples. There is no lower control limit for an _____, since a result of zero would mean no variation exists in the samples, which would be desirable. - Measures the degree of variability in samples - Plots the range of results

Conformance

In production or service provision, operations can range from being in ____ to having too much variation to be effective. ____ means that the product has been manufactured or the service provided within predetermined specifications and standards and that no adjustments to the process need to be made. _____ is an affirmative indication or judgment that a product or service has met the requirements of a relevant specification, contract, or regulation.

Continuous Improvement

It also is important to recognize a key principle of standardized work. Although it is a standard method for making a product, the standard itself should regularly change as a result of _____. This could be improvements in production techniques such as setup time and lot-size reduction or reduction in administrative and documentation time.

Benchmarking Process Benchmarking

Juran's Quality Handbook lists key tasks in the ______: 1. Determine Critical Performance to benchmark that provides a competitive advantage and aligns with the KPIs in the strategic plan 2. Define the metric that will be used 3. Identify leading or benchmark targets 4. Gather the organization's own performance data 5. Identify and analyze performance gaps 6. Plan a path forward 7. Allocate resources Juran's Quality Handbook notes that in effective ____, the findings are integrated into the organization's performance management system. In addition, the process itself becomes part of the organization's infrastructure. It is repeated regularly so that the organization can be sure that it is still measuring itself against the best standards.

Timeliness Participation Method Level of Detail

Juran's quality handbook explains four reasons why training programs fail: 1. ________: Training is not provided when the knowledge or skill will be used. 2. _______: The right individuals are not involved in the creation of the training materials so they are not relevant to the audience. 3. ______: The training relies too heavily on lecture versus hands-on experience. 4. _______: Information is not taught at a level that the audience can understand.

Flow Pull Flow Pull

Lean Systems use ____ and ____ to reduce work-in-process (WIP) inventory, and for many organizations, this is a key area for continuous improvement. Organizations could adopt some of the methods discussed here even if they are still traditional manufacturers for the most part. _____ seeks to eliminate queues and thus the inventory between workstations. Items are pulled from the prior workstation as needed rather than being pushed without regard to need. In this way, _____ reduces the build-up of WIP inventory.

Changeovers x3

Manufacturing processes and even services have periods of time when equipment is unavailable due to tooling, material, part, program, or service area layout changes. ___ must be performed while the equipment is stopped, but equipment and related procedures can be designed to dramatically reduce the required shutdown time. Reducing ___ time unlocks more productive (value-added) time for running production. Reducing _____ time can also reduce production batch sizes, work in process, and inventory.

Cells Virtual Cell(s) x4

One example of work area design that reduces mistakes is the use of ____ that are an arrangement of people, machines, and materials that are ordered in sequence to match the process flow. If it is impractical to move the equipment, the organization may choose to utilize _____.. A _____ is a logical rather than physical grouping of manufacturing resources. Resources in ____ can be dispersed throughout a facility. Product mix changes may change the layout of a _____. This technique is used when it is not practical to move the equipment.

Training Programs

One of the most important aspects to assist with efficient scheduling is the ability to determine workload requirements and priorities. Given this information, the next challenge is to have enough qualified workers for the given load. However, _____ that effectively help workers to become cross-trained or even just trained in a primary job are difficult to design.

Single Minute Exchange of Die (SMED)

One technique is ____: the concept of setup times of less than 10 minutes, developed by Shigeo Shingo in 1970 at Toyota.

Statistical Process Control

Organizations often use _____ and its tools (including various types of control charts) to identify the level of variation over time relative to organizational or industry standards. The application of statistical techniques to monitor and adjust an operation. Often used interchangeably with statistical quality control, although statistical quality control includes acceptance sampling as well. ____ is a method of quality control in which statistical methods are used to monitor and control a process. Monitoring and controlling the process ensures that it operates at its full potential. At its full potential, the process can make as much conforming product as possible with a minimum (if not elimination) of waste, rework, or scrap - the application of statistical analysis tools to control process inputs (independent variables)

Control Chart(s)

Organizations use statistical process control methods to identify variation and the level of adherence to organizational or industry standards using _____. A _____ is a graphic comparison of process performance data with predetermined computed control limits. The process performance data usually consists of groups of measurements selected in the regular sequence of production that preserve the order. The primary use of _____ is to detect assignable causes of variation in the process as opposed to random variations.

Simplify

Organize the remaining items. Set in order. A place for everything. Why is it important: Eliminates many kinds of waste, including Waste due to need to search for items Waste due to difficulty in using items Waste due to difficulty in returning items. Examples: Place tools close to the area where they are needed. Assign locations for tools and equipment to be kept, and label them so they can easily be found, e.g., use silhouettes of the tools.

Attribute Sampling

Process Steps for ______: 1. Take a sample of a specified quality characteristic for each unit. Each unit is classified as acceptable or defective. 2. Summarize these into a simple statistic, such as sample average. 3. Compare the observed values to the allowable standard values defined in the quality plan. 4. Make a decision to accept or reject the lot.

Manufacturing Execution Systems

Programs and systems that participate in shop floor control, including programmed logic controllers and process control computers for direct and supervisory control of manufacturing equipment; process information systems that gather historical performance information, then generate reports; graphical displays; and alarms that inform operations personnel what is going on in the plant currently and what occurred during a very short history into the past. Quality control information is also gathered and a laboratory information management system may be part of this configuration to tie process conditions to the quality data that is generated. Cause-and-effect relationships can thereby be determined. The quality data at times affects the control parameters that are used to meet product specifications either dynamically or off line.

Nemawashi

Promotion of _____ (the Japanese term for consensus building). Collaboration, seeking information and opinions from others, and reaching consensus among all interested parties are important objectives of the A3 report.

Setup TIme

Reducing ____ increases operation velocity and throughput. ____ is the time required for a specific machine, resource, work center, process, or line to convert from the production of the last good piece of item A to the first good piece of item B.

Sort

Sort out what you don't need. Eliminate anything that is not truly needed in the work area. If in doubt, throw it out Why is it important? Space, time, money, energy, and other resources can be managed and used most effectively. Reduces problems and annoyances in workflow. Improves communication between workers. Increases product quality. Enhances productivity. Example: Red tagging. Designating areas for collection of items to be sold, donated, recycled, disposed of, etc

Takt Time Work Sequence WIP

Standardized work is critical to lean manufacturing. By standardized work, we mean work that adheres to several core standards. In the case of lean, standards include: 1. ______ for the manufacturing of products based on the rate of customer demand 2. _______ of the process designed for particular products 3. _______, or how much inventory there should be for particular products.

Technology Automation

Technology and automation can be a competitive advantage in today's manufacturing world. ______ can enable superior connectivity and information leverage. ____ has allowed companies to mass-produce products at outstanding speeds and with great repeatability and quality.

PDCA Cycle

The A3 report provides a vehicle for moving systematically through the steps of the _____ while documenting assumptions, plans, the results of pilot implementation, and countermeasures proposed before full-scale implementation.

Five S's

The _____ create a work environment that supports successful lean scheduling; they are a foundation of total productive maintenance. ____ is used to create a workplace suitable for lean production: sort, simplify, scrub, standardize, and sustain. Goals of a _____ program: 1. Reduce waste 2. Reduce variation 3. Improve productivity

A3 Report

The _____ is a product of A3 thinking. The ____ gives structure and impact to the A3 thinking and fosters effective ways of working and behaving by those involved in developing the ____

A3 Report Objective

The _____ should meet two criteria: 1. Clearly defined target state with measurement criteria for determining if the goal has been reached; for example, reduce scrap rate in processes X and Y to 2 percent by the end of the year 2. Measurement data that are collectible for use in confirming the effectiveness of the improvement

Acceptance Sampling

The advantages of ______ over full inspection are: 1. smaller staff requirements 2. less damage to goods 3. reduced time and costs.

Acceptable Quality Level

The allowable standards, as defined in the quality plan, are referred to as the _____: When a continuing series of lots is considered, a quality level that, for the purposes of sampling inspection, is the limit of a satisfactory process average. Sampling standards that can be used include ANSI/ASQC Z1.4-2003 (R2018), Sampling Procedures and Tables for Inspection by Attributes, and ANSI/ASQC Z1.9-2003 (R2018), These standards contain precalculated sample sizes for different-size lots depending on whether the organization is using tightened, normal, or reduced sample size plans.

Pull System

The basic _____ has no timing associated with operations in the product routing. Whenever a customer needs a part, the _____ responds by replenishing the part previously supplied. This system is asynchronous.

Control Limit(s)

The control chart for such a process has most of its data points within the statistical ____. They are a statistically determined line on a control chart (upper control limit or lower control limit). If a value occurs outside this limit, the process is deemed to be out of control.

Training Programs

The definition of training failure is that the program does not result in the desired change in behavior. Therefore, effective ______: 1. Need to be provided just-in-time. 2. Material preparation and training delivery needs to be a team effort. 3. Training teams need persons who have expertise in the area and in training material preparation and who are good at training delivery. 4. The training should have a work simulation or on-the-job work phase that immediately follows or is integrated into self-study or classroom training components.

Coupling and Connectivity Coupling

The downsides of _____ and _____ include: 1. Integrated technology is expensive 2. It exposes the manufacturing system to more risk because a failure in one part of an interconnected system will affect the entire system, and it best accommodates a standard flow of parts _____ has a tradeoff with flexibility and is more suited to the cost advantages of relatively high volume and low variety. Therefore, no one type of layout is the best in all situations.

A3

The following are three key points with regard to the ___ technique: 1. It is a problem-solving approach built around PDCA or DMAIC. 2. The problem-solving A3 report process unleashes the true power of the PDCA or DMAIC process. 3. The A3 report is an important visual communication link between workers and management involved in the improvement effort.

Manufacturing Specifications x2

The idea behind _____ is to define the measurement values which correspond to conforming items. That is, when the measurement falls within the ______, then the product can either move to the next step in the process or, if complete, be shipped to the customer. The organization needs to set specific limits that reflect the functional needs and manufacturing variability. For products that fall outside of the _____, the loss is the cost to replace the product. Organizations should keep a close watch on the volume of products that fall outside of the ________.

Variable Sampling

The numerical magnitude of a characteristic is measured and recorded for each inspected unit. This type of sampling involves reference to a continuous scale of some kind (for example, measurement of length).

Acceptance Sampling

The process of sampling a portion of goods for inspection rather than examining the entire lot. The entire lot may be accepted or rejected based on the sample even though the specific units in the lot are better or worse than the sample. two types of _____: 1. Attribute sampling 2. Variable sampling

Variable Sampling

The process steps for _____ are as follows: 1. Take a sample and a measurement of a specified quality characteristic for each unit. 2. Summarize these into a simple statistic, such as a sample average. 3. Compare the observed values to the allowable standards defined in the quality plan. 4. Make a decision to accept or reject the lot.

Work Area x2 Work Area Design Work Area x3

The purpose of the ____ is to produce product. Before determining the design of the ___, the manufacturing process, product type, and production layout need to be determined. As a manager, one of your goals in ______ is reducing the number of mistakes. This can be accomplished through standardizing and mistake-proofing the manufacturing environment and its _____. The manager uses charts to develop standardized work and define the _____. Examples include: 1. Production capacity chart—used to determine the capacity of the machines within the process 2. Standardized work combination table—used to identify work elements and the sequence required in order to design the work appropriately 3. Standardized work analysis chart—used to provide the foundation of the layout and to train workers 4. Job element sheets—used to outline a group of actions to advance a process.

Go/no-go

The state of a unit or product. Two parameters are possible: go (conforms to specification) and no-go (does not conform to specification).

Sprint Standup Scrum master Scrum

The team meets on a regular basis and plans tasks that can be done before the next regular meeting. Each fixed time period is called a _______ . In the meeting, the team can repriortize the items in the backlog (moving the most important cards to the top) and update the status of tasks by moving a card to a new column. A goal is to keep the team focused on current work before starting too many new things. The team also meets briefly on a daily basis, a ______, to discuss what they did, what they are doing, and any problems. At the end of the sprint, they review lessons learned and decide on ways to improve the process (a retrospective). Rather than using a formal project manager, a _____ is used. This person ensures that the ____ methodology is used and works to remove obstacles while letting various team members take the lead as needed. A product owner role represents the needs of the customer. (This could be an internal customer.)

Yield

The use of statistical process control will impact _____, which is the amount of good or acceptable material available after the completion of a process. Usually computed as the final amount divided by the initial amount converted to a decimal or percentage. In manufacturing planning and control systems, ____ is usually related to specific routing steps or to the parent item to determine how many units should be scheduled to produce a specific number of finished goods. For example, if 50 units of a product are required by a customer and a ___ of 70 percent is expected, then 72 units (computed as 50 units divided by .7) should be started in the manufacturing process.

Seeing Knowing Acting

The visual management triangle encompasses: 1. _____ as a group: Production status, inventory levels, and machine availability 2. _____ as a group: Delivery commitments, goals and schedules, management rules 3. ______ as a group: Consensus on rules and objectives, involvement in improvement activities

Reduce Setup Time

There are five steps to ________: 1. Classify internal and external changeover tasks. Internal tasks must be performed while a machine is stopped (idle time); external or preparation tasks can be performed while the machine is still running. 2. Convert internal setup tasks to external tasks. For example, organize tools and materials for setup while the machine is still running a batch. 3. Streamline internal setup. For example, find ways to reduce the time it takes to fasten equipment in place. 4. Eliminate adjustments. Documenting the proper adjustments for different materials helps eliminate wasteful trial and error as adjustments are repeated until the machine produces an "in spec" product. 5. Minimize external (preparation) time, since small batch processes may not provide enough time to prepare for the changeover.

Workplace layouts

There are several common ______: 1. Islands 2. Connected Islands 3. Connected islands with full work control 4. Cells

Specification Limits

Unlike upper and lower ____ , which are set by customer specifications, control limits are established by statistical observation of variability and are assessing if the process itself is in control

Current State Map Future State Map

Value stream maps are best prepared by working backward from the finished product or service through various processes while timing each step. The map includes information about changeover time in minutes (C/O) and cycle time in minutes (C/T) at each work center and inventory (I) at each stage in the process. Typically, organizations first create a _____ Then they determine areas for improvement and create a modified ______. Non-value-added tasks will be examined first and removed or modified if possible. Use of the value stream mapping technique can result in 1. Improved inventories 2. Improved cycle times 3. Improved throughput

First Time Through

Visual Workplace Reporting: ________ _____ = Total units produced - rejects - returns

Work Area Design

Ways to improve ____ consist of: 1. Workplace organization 2. Setting specifications 3. Standardized work 4. Work orientations 5. Workflows 6. Layouts 7. Changeovers 8. Simulation and modeling 9. Automation 10. Training 11. Visual techniques 12. 5S's

Total Productive Maintenance

With _____, machine operators are trained in routine service and conduct preventive maintenance on their machines. Operators may also observe or assist when a more-skilled technician is required to make repairs. This helps operators increase their understanding of how their machines function. It also increases their sense of responsibility for their machines. This sense of ownership matches the lean philosophy of employee empowerment. There are additional benefits, such as Extending the life of equipment and protecting the organization's capital investments Improving worker safety Making the system more resilient. There is available capacity to manage unexpected interruption.

X-Bar Chart

With the ______: the mean of the process as it was designed to operate (population mean) is placed as the central line on the chart. The upper and lower control limits are then calculated using the laws of probability. Control limits are typically set at plus or minus three standard deviations from the mean. Thus, if the process is in control, the samples will fall within the control limits 99.7 percent of the time. When variation exceeds the statistical control limits, it is a signal that special causes have entered the process and must be investigated - the sample observation means are placed on the chart at each observation period and are connected by lines to show upward or downward movement - the population mean will be at the center

Workplace Organization

Work area design and _____ help integrate various manufacturing and assembly areas. Areas are linked by storage, transportation, and handling systems. ____ is the arrangement of tools, equipment, materials, and supplies according to their frequency of use. Those items that are never used are removed from the workplace, and those items that are used frequently are located for fast, easy access and replacement. This concept extends the idea of "a place for everything and everything in its place."

Islands

Workers in each _____ (process) produce at their own pace, usually as fast as they can. ____ are connected by independent materials-handling equipment such as forklifts. Flow volume depends on the upstream ____ production rate and move schedule.

Attribute Sampling

___: The presence or absence of a characteristic is noted in each of the units inspected. No measurements are needed. For example, the use of a go/no-go gauge is either pass or fail.

Standardized Work

____ is based on principles of motion economy and ergonomics. For this reason, workplace design needs to address the following: 1. The flow of work through choice and improvement of tool, equipment, and workplace layout design 2. Optimizing coupling and connectivity

Simulation

____ is often done at various throughput volumes and with various pieces of the system integrated at a time, such as to determine where a bottleneck might appear. Discrete event _____ can replicate only situations that have distinct, recognizable events and operations.

Sort Simplify Scrub Standardize Sustain

____ means to separate needed items from unneeded ones and remove the latter. ____ means to neatly arrange items for use. ____ means to clean up the work area. ____ means to sort, simplify, and scrub daily. ____ means to always follow the first four Ss. Sometimes referred to by the Japanese equivalents: seiri, seiton, seiso, seiketsu, and shitsuke.

Control Chart(s)

____ show sample data over time. A _____ is based on a series of samples taken over time. An assumption is that all samples are taken from the same process—that is, that the setup, materials, and other conditions are standardized. Ideally, only common causes should be present in a process, because these represent a stable, predictable process.

Enterprise Resources Planning System (ERP System)

____: Framework for organizing, defining, and standardizing the business processes necessary to effectively plan and control an organization so the organization can use its internal knowledge to seek external advantage. An _____ provides extensive databanks of information including master file records, repositories of cost and sales, financial detail, analysis of product and customer hierarchies, and historic and current transactional data.

Statistical Quality Control

____: The application of statistical techniques to control quality. Includes acceptance sampling as well as statistical process control, but is often used interchangeably with statistical process control. ___ is the application of the statistical analysis tools to monitor process outputs (dependent variables). ____ is therefore a broader concept that encompasses both statistical process control and acceptance sampling.

Control Charts

_____ analyze performance to identify the need for root cause analysis of special-cause variations (variations other than random variations that are expected in the process).

Scrum

_____ is an agile project management technique that can be used for projects with a lot of requirements variability. ____ is a rugby term that implies that the team needs to move forward as a unit by letting various members take the lead as needed. ____ can be used to prioritize and reprioritize continuous improvement tasks or mini-projects (i.e., kaizen events) such as to alleviate a new bottleneck area. The basic process is to create a visual board that has cards with all of the work to do (a backlog) in the first column, all the work in process, perhaps in various stages in one or more columns, and the work that is done in a final column. This is called a kanban board or ___board. (It was inspired by lean kanban boards.)

Total Productive Maintenance

_____ is preventive maintenance plus continuing efforts to adapt, modify, and refine equipment to increase flexibility, reduce material handling, and promote continuous flows. It is operator-oriented maintenance with the involvement of all qualified employees in all maintenance activities.

Tools and Equipment Layout

_____ should consider three principles: 1. Economy of motion in obtaining, using, and returning tools 2. Visibility of tools to facilitate finding and selection 3. Ergonomics of using, lifting, and moving of tools and materials

A3

_____ thinking and problem solving bring structure and discipline to the plan-do-check-action (PCDA) cycle. ____ is a component of lean but can be applied by any type of organization. Problems in an organization are often addressed superficially. The deeper, underlying causes of problems are not always considered. The same problems will resurface, with the result that operational performance does not improve. The ____ thinking process helps to arrive at a joint and detailed problem resolution. Underlying causes are thus eliminated.

Lean Production

_____ tools used to address the reduction of WIP and lead time include Value stream mapping Pull systems Setup reduction Total productive maintenance.

Upper Control Limit (UCL) Lower Control Limit (LCL)

_____: . This is the "control limit for points above the central line in a control chart" (Dictionary). Any data point above this line is considered to be out of control. ____: This is the "control limit for points below the central line in a control chart" (Dictionary). Any data point below this line is considered to be out of control.

Common Causes (random causes)

_____: Causes of variation that are inherent in a process over time. They affect every outcome of the process and everyone working in the process.

Connected Islands with Full Work Control

_____: Islands are connected by conveyors. There is visual control over the rate of flow between processes: The upstream process stops producing when the downstream process's inbound parts bin is full, thus preventing overproduction.

Cells

_____: Machines are next to each other. One piece is made at a time and moved when completed to the next machine. Benefits to working in _____ include ease of team member communications, ready assistance, on-the-job cross-training, instant feedback regarding errors, and no room for work in process due to limited space.

Computer Aided Design (CAD) Computer Aided Manufacturing (CAM)

_____: The use of computers in interactive engineering drawing and storage of designs. Programs complete the layout, geometric transformations, projections, rotations, magnifications, and interval (cross-section) views of a part and its relationship with other parts. ____: The use of computers to program, direct, and control production equipment in the fabrication of manufactured items.

Central Tendency Data Point

_____: This is where the process typically tends to run. It may or may not be ideal. ____: This is a sample of measurements taken at a specific time. Sample averages are determined and plotted, as they show a change in variation faster than a single discrete sample.

Connected Islands

______ (processes) are connected by conveyors, but there is no control over the rate of flow. Workers still build at their own pace.

Common Cause (random)

______ variation leads to predictable and stable variation in the process output. This is called being in the state of statistical control, or sometimes just in control. ____ behave like a stable system of chance causes. If only _____ of variation are present and do not change, the output of a process is predictable. If the outputs in this state are in conformance the vast majority of the time, then this type of variation is not a problem. This is the ideal situation. _____ variation results from numerous uncontrollable, everyday factors such as unregulated environments, operators, raw material variations, and more. However, if ____ variation results in nonconformance too often, this is a chronic problem that needs fixing. It will be difficult to fix. -identifying ______ by category can help, because people can design a process to minimize their impact. Categories: people, environment, materials, measurement, methods, machine

Computer Integrated Manufacturing

______: The integration of the total manufacturing organization through the use of computer systems and managerial philosophies that improve the organization's effectiveness; the application of a computer to bridge various computerized systems and connect them into a coherent, integrated whole. For example, budgets, CAD/CAM, process controls, group technology systems, MRP II, and financial reporting systems are linked and interfaced.

Simulation

______: The technique of using representative or artificial data to reproduce in a model various conditions that are likely to occur in the actual performance of a system. Frequently used to test the behavior of a system under different operating policies. 2) Within MRP II, using the operational data to perform what-if evaluations of alternative plans to answer the question, "Can we do it?" If yes, the ___ can then be run in the financial mode to help answer the question, "Do we really want to?"

Value Stream Mapping

______: can be used for WIP and lead-time reduction, but it can also be applied to many types of continuous improvements or breakthrough improvements. ______ visualizes the flow of the value stream, the process steps from raw material to finished goods (or delivery of service to the customer). It typically shows multiple process levels and the linkages among them. Typically, the upper portion of the map contains the information flow, the middle portion contains the material flow, and the lower portion contains the process data and a time line that differentiates between value-added lead time (processing time) and non-value-added lead time (wait and move times) so the organization can find ways to reduce the non-value-added lead times.

Total Productive Maintenance

______: is proactive and focuses on opportunities as well as threats. It does not wait until a machine breaks down or until quality problems occur before servicing the equipment. This has numerous benefits that address operational performance objectives. It reduces downtime, which in turn reduces delays in downstream processes, which improves dependability. It improves quality, since technology is more likely to produce product within statistical controls. Greater dependability improves costs by requiring less inventory buffer. By focusing on productivity, ____ triggers continuous technology and process improvements.

Visual Workplace

the principle is that everything a worker needs to do his or her job is visible and all production activities should also be visible to the supervisor. Visibility enables the supervisor and workers to see work-in-process levels and correct them as needed.