Lean Manufacturing Definitions
This glossary of lean manufacturing definitions, whilst not exhaustive, will provide explanations to many of the terms used in your lean manufacturing training.
The definitions contained here may have slightly differing meanings, dependant upon the context in which they are used but as a general guide you will find them pretty accurate.
Any lean manufacturing definitions that appear in blue and underlined, when clicked will open a new window with a more in-depth explanation of the term
Lean Manufacturing Definitions
A3 reports, how to write them, what they should contain
Agile Manufacturing -
In essence, it is the ability to thrive under conditions of constant and unpredictable change. Like flexible manufacturing, agile manufacturing seeks to achieve rapid response to customer needs. But agile manufacturing also emphasizes the ability to quickly reconfigure operations and strategic alliances to respond rapidly to unforeseen shifts in the marketplace. In some instances, it also incorporates "mass customization" concepts to satisfy unique customer requirements. And, in the broadest sense, it includes the ability to react quickly to technical or environmental surprises.
Andon described in full (Lantern)-
A signal, light, bell, music alarm, triggered by an operator confronted with a non-standard condition. Tool failure, machine failure, bad part, lack of parts, cannot keep up; error needs correction, etc. The signal for immediate help to prevent line stop.
Andon Board -
A visual control device in a production area, typically a lighted overhead display, giving the current status of the production system and alerting team members of emerging problems.
Annual Inventory Turns -
A measure that is calculated by dividing the value of annual plant shipments at plant cost (for the most recent full year) by the total current inventory value at plant cost. Total current inventory includes raw materials, work in process, and finished goods. Plant cost includes material, labor, and plant overhead.
Autonomation (English translation of Jidohka) -
A form of automation in which machinery automatically inspects each item after producing it, ceasing production and notifying humans if a defect is detected; Toyota expands the meaning of jidohka to include the responsibility of all workers to function similarly, i.e. to check every item produced and to make no more if a defect is detected, until the cause of the defect has been identified and corrected.
Baka-yoke
(Idiot or Fool Proofing) a manufacturing technique of preventing mistakes by designing the manufacturing process, equipment, and tools so that an operation literally cannot be performed incorrectly; an attempt to perform incorrectly, as well as being prevented, is usually met with a warning signal of some sort
Blitz - see kaizen
Cellular Manufacturing -
A manufacturing approach in which equipment and workstations are arranged to facilitate small-lot, continuous-flow production. In a manufacturing "cell", all operations necessary to produce a component or subassembly are performed in close proximity, thus allowing for quick feedback between operators when quality problems and other issues arise. Workers in a manufacturing cell are typically cross-trained and, hence, able to perform multiple tasks as needed.
Chaku-chaku -
A method of conduction single-piece flow in which the operator proceeds from machine to machine, taking a part from the previous operation and loading it in the next machine, then taking the part just removed from that machine and loading it in the following machine. Means "load-load" in Japanese.
Concurrent Engineering -
A cross-functional, team-based approach in which the product and the manufacturing process are designed and configured within the same time frame, rather than sequentially. Ease and cost of manufacturability, as well as customer needs, quality issues, and product life cycle costs are taken into account earlier in the development cycle. Fully configured concurrent engineering teams include representation form marketing, design engineering, manufacturing engineering, and purchasing, as well as supplier and even customer companies.
Continuous Improvement -
A never-ending effort to expose and eliminate root causes of problems; small-step improvement as opposed to big-step or radical improvement. Syn: kaizen.
Cpk -
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