Ch. 8

lean six sigma

a methodology that combines the organizational elements and tools of six sigma with Lean's focus on waste reduction

Just-in-time (JIT)

a philosophy of manufacturing, applicable to manufacturing and services based on planned elimination of all waste and on continuous improvement of productivity (older name)

Lean production

a philosophy of minimizing the resources needed for processes

kanban system

a production control approach that uses containers, cards, or visual cues to control the production and movement of goods through the supply chain

pull system

a production system in which actual downstream demand sets off a chain of events that pulls material through the various process steps

-Matches supply with varying demand -allows production of a variety of products on the same equipment -aids in overcoming defective materials, late deliveries, equipment failures, mistakes, etc.

Objectives of inventory

process analysis/value stream mapping

a graphical analysis flow through a process

lean supply chain management

an extension of the lean philosophy to supply chain efforts beyond production and seeks to minimize the level of resources required to carry out all the supply chain activities

Toyota Production System

another name for lean systems, specifically as implemented at Toyota

lean waste

any activity that does not add value to the good or service in the eyes of the consumer

group technology

bring together resources to process a family of items

Mixed model (heijunka)

build smaller quantities more frequently (match production of demand)

supplier goal

deliver small lots of high quality components on time

5-S

effective housekeeping (sort, straighten, scrub, systematize, standardize)

overproduction, waiting, unnecessary transportation, inappropriate process, unnecessary inventory, unnecessary/excess motion, defects, underutilization of employees

eight lean wastes

quality at the source

eliminating defects at their origination points

Do NOT accept scrap, waste, defects, or inventory

lean philosophy

Kanban (pull)

output generated in response to actual demand

visual control

performance and problems easily, immediately visible

focused factories

processes designed to satisfy specific customer segment

JIT production

produce in small lots to replenish stock that is actually sold

producer goal

produce small lots of high quality products with low inventory

Paka-Yoke

redesign so mistakes are impossible or immediately detectable (fail-proof a process)

Simplification/Standardization

removing non-value add steps, making processes exactly repeatable

Kaizen Events

short-term, cross-functional focused, intense process improvement

set-up reduction

shorter, easier change-over leads to smaller batches

takt time

synchronizing output rate with demand rate

statistical process control (SPC)

use of statistical tools to monitor processes and their performance

muda

way to say lean waste in Japanese

total productive maintenance (TPM)

works to identify and prevent all potential causes of breakdowns