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5
Why’s
A
method
of
problem
solving
that
involves
asking
”Why”
a
number
timesuntiltherootcauseofaproblemisdetermined.
5sWorkplaceOrganizationProcess:
1Sort(clear
2Straighten(Organize
3Sweep(Clean
4Standardize(maintain
5Sustain(ContinuousImprovement
6SigmaSixsigmaisarigorousproblemsolvingprocessfocusedonreducingvariationandmatchingcustomerrequirementstoprocesscapability.SixSigmaprocessknowledgeenablesachievingqualitytargetsthatmaximizecustomervalue
A3One-pagereportformatthatincludesalltheinformationneededforthereadertoMakeadecisiononastatedPROPORSALorPROBLEM,orCommunicatetheSTATUSoforplansforaspecificgoal
ActualRuntime=(ScheduledRuntime-(Downtime+LostTime+ChangeoverTimeAddressSystemAstandardlogicalalphanumericsystemthatidentifiesuniquelocationsthroughoutthefacility
AndonSystemAproductionManagementvisual/audiocontroltool,activatedmanuallyorautomatically,tomonitorstatusandtoaidinemergencyresponsebycommunicatingtosupportresourcestheneedforassistance
AreaInformationcenterAnareaonornearthemanufacturingfloordedicatedtoprovidingpropercommunicationsforproductionpersonnelinateamenvironmentAutonomationAmachinecanstopitselfbyusingitsownjudgement.Sometimesreferredtoasautomationwithahumantouch
BeliefsandValuesGroupofstatementsthatdescribebasicprinciplesanorganizationBenchmarkStandardbywhichaproduct,process,procedureetc.CanbemeasuredorBenchmarkingContinuoussystematicprocessforevaluationtheproducts,servicesandworkprocessesoforganizationsthatarerecognizedasrepresentingthebestpracticesforthepurposeoforganizationalimprovement
BulkStorageSeeSupermarket/bulk
Card
Pull
system
uses
“Production
“to
authorize
build
parts
and
“Withdrawal
Card”
to
the
movement/shipment
parts
ChangeoverTimeProductiontimelostduetopartnumberchangeover
Clean(sweepProcessthatrequiresinspectionandevaluationfortheworkareafordirt,debrisandfluidleaksandensuresthatirreversiblecorrectiveactionsareimplementedClear(sortRequiresthateverythingstoredattheworkstationisusedonafrequentbasisandthateverythingelseisstoredawayfromtheworkstation
CommonLotStrategyReducingvariationinthematerialflowpipelinethroughtheuseoffactorsofsixtystandardpack/standardlotquantities.(60,30,20,15,12,10,6,5,4,3,2,1CommunicationModelStructuredprocessforinformationsharingandexchangethatisimplementedandunderstoodbythewholeorganization
7waste
Correction
Overproduction
Materialmovement
Motion
Waiting
Inventory
Processing
ConstraintThatbottleneckwhichmostseverelylimitstheorganizationfromachievinghigherperformancetowardsitsgoalorpurpose
ConstraintsmanagementsAtoolwhichenablestheorganizationtoquicklyfocusimprovementeffortsinaspecificarea
ContainerordollyexchangepullsystemMaterialpullsystemthatusesanemptycontainerordollyasaphysicalsignalthatauthorizesthesuppliertoreplacetheamountofContainerreturnprocessTheorderlyprocessofcollecting,sorting,stagingandreturningdamagefreereusablecontainersanddunnageinatimelymannertosuppliersContainerizationPackagingpartsinthesmallestlotpossibleresultinginthepresentationofaqualitypartinamannerthateliminatesthewasteofmotionfortheoperatorContinuousimprovementprocessSystematicapproachthatleadstotheidentificationandeliminationfowasteandtoimprovedlevelsofperformance
DailyproductionreportAhardcopyversionoftheproductionstatusboardwhichshouldbeusedineveryproductionarea
DeliverypullSeewithdrawalpull
DeliveryroutesSeeinternaldelivery
DelphimanufacturingsystemAflowbasedstructuremanufacturingsystemdesignedtotransformandcontinuouslyimproveoperationstosupportcustomerneeds.
Delphiproductdevelopmentprocess(PDPProvidesastructuredprocesstoeffectivelydesign,developandimplementnewproductsand.orprocessestomeetcustomer
Designformanufacturabilitymachineandtooldesign(DFM-M&
TDAninitiativetoanalyzeandimprovethedesignoftools,equipmentandprocessfromalifecyclecostDGPDelphiglobalpurchasing
DowntimeProductiontimelostduetoequipmentonly
EducationandtrainingAformalizedtrainingplanbasedonastructuredmethodofidentifyingtrainingneedstosupportcontinuousimprovement
Effectiveavailableminutes=(minutespershift-(approvedbreaks
ElectronicpullAsystemusingelectronicsignalgeneratedbykeypunch,scaningorelectronicsensortosignaltheneedformaterialreplenishmentatapredeterminedreorderEliminationofwasteTheprocessofidentifyingandeliminatingthesevenformsofEmergencymaintenanceFunctionofquicklyrespondingtoandrepairingajobwhenmaintenanceissignaled,havingalloftheskillsequipmentandpartsavailabletorepairtheemergencybreakdowninstantlyandefficientlywithoutbarriersorroadblocks
EmployeeenvironmentandinvolvementAllpeoplewithinanorganizationworkingasateamtocontinuouslyimproveandaccomplishthemanufacturingobjectives.
EmptycontainerstorageDesignatedareatostorereturnablecontainersreceivedfromcustomersand/orstagedforshipmenttosuppliers
ErrorproofingProcessofanticipating,preventinganddetectingerrorswhichadverselyaffectcustomersand/orresultinwaste
EscalationgprocedureAnestablisheddocumentedandunderstoodstandardprogressionofeventsthatisdevelopedtoaddresslosttimeanddowntimeresponse.
ExternalpullSeesupplierpull
ExternalsetupChangeoverstepsthatcanbeperformedwhileamachineisrunningFlowmanufacturingAtime-basedprocessthatpullsmaterialthroughaproductionsystemwithnointerruptionattherateofcustomerdemand
GapassessmentProcessforconsistentmeasurementandevaluationofDMSHazardousmaterialplanRequiredsothatmaterialinourplantsishandledintheappropriatemannertoensurethehealthandsafetyofourworkforce
HeijunkaSeelevelscheduling
IndirectmaterialplanRequiredsothatmaterialinourplantsishandledintheappropriatemannertoensurethehealthandsafetyofourworkforce
InternalauditsAuditsperformedbyanorganizationonitselfusingitsownpersonnelInternaldeliveryroutesAsystemtoreplenish/removeemptycontainersandmaterialbasedonapredetermineddeliverypathandfixedstarttimessupportingpulldeliverytoaspecificnumberofproductiondeliverypointsofuse
InternalsetupChangeoverstepsthatmustbeperformedwhilethemachineisstoppedInventoryturnsAninventorymeasureobtainedbydividingannualsalesatcostbytheaverageaggregateinventoryvaluemaintainedduringtheyear.
FORMULA__inventoryturns=annualsales(atcost/Averageinventoryvalue
JidokaSeeautonomation
Just-in-timeproduction(JITSeeflowmanufacturing
KaizenJapanesetermforcontinuousimprovement
KanbanSeecardpull
KanbanpostTheboxorboardthatisusedtocollectpullcards.
KittingAprocessofgroupingpartsintosetsthatareusedtogetherinadownstreamLeadtimeSeetotalproductcycletime
LeanlogisticsAclosedloopsystemofmaterialdeliveryandcontainerreturnfromsuppliertocustomersmanagedbyaleadlogisticssupplier(LLP
LevelschedulingSeeproductionleveling
LinearcycletimeThepaceatwhichallmachinesmustbecapableofrunning
LosttimeAllreasonsforproductionlossnotincludedindowntimeandchangeovertimeLotsizepullAmaterialpullsystemthatusesasinglepullsignaltoindicatethesizeofalotthatshouldbeproducedandwhenitshouldbeproduced
MachineprocesscapabilityAnalysistoolusedtoevaluatestabilityandnaturalcontrollimitsofamachineorprocesscomparedtothespecifications
MachinequalificationValidationofnewormodifiedproductionequipmentbyMachineryandequipmentspecificationsTogetherwithappropriatestandardsdescribestherequirementstobemetbyequipmentandsupplies.OA-8EspecificationsdemaquinariayMaintain(standardizeStandardsystems(labels,documentedandunderstoodstandardprogressionofeventsthatisdevelopedtoaddresslosttimeanddowntimeresponse,colorcodingetc.thatreadilyidentifyabnormalconditions
MaintainabilityAcharacteristicofdesign,installationandoperation,usuallyexpressedastheprobabilitythatamachinecanberetainedin,orrestoredto,specifiedoperableconditionwithinaspecifiedintervaloftimewhenmaintenanceisperformedasprescribed.MaintenancepartskittingProcessoforganizingallcomponentsnecessarytocompleteaworkorderintoonecontainer.
MAPSProblemsolvingprocessusedtoidentify,analyzeandeliminatethegapbetweenourcurrentanddesiredstatetoachievecustomersatisfaction
MaterialmovementAprocessthateffectivelymovesmaterialthroughthemanufacturingoperationstosupportflowstrategyresultinginthedeliveryoftherequiredquantityofproducttothecustomerontime
MeasurementsystemanalysisPerformedtodetermineifthemeasurementsystempossessestherequiredstatisticalpropertiesandtodiscoverwhich,ifanyenvironmentalfactorshavesignificantinfluenceonthemeasurementsystem
Measurement/feedbacksystemMethodsofcommunicationthatareutilizedtoprovideacommonunderstandingofinformationthroughouttheorganization
MixedmodelproductionSeeproductionleveling
MSDManufacturingsystemdesign(seeflowmanufacturing
MudaJapanesetermforwaste
MuraJapanesetermforfluctuation
MuriJapanesetermforunreasonablepractices
Nat