Kaizan
• Kaizen means continuous improvement
• involves everyone in the organization in small improvements using
conventional knowledge and tools
• without large capital investments
• focusing on eliminating waste
• If something can be improved, a measure must exist by which improvement can
be quantified – quality characteristics
5’S
• 5S represents 5 disciplines for maintaining a visual workplace (visual
controls and information systems)
• Foundational to Kaizen
Kanban
• Kanban is the term used for the visual & physical signaling system that ties
together the whole Lean Production system
• Visualize the workflow
• Split the work into pieces, write each item on a card and put on the wall.
• Use named columns to illustrate where each item is in the workflow.
• Limit WIP (work in progress) – assign explicit limits to how many items may
be in progress at each workflow state.
• Measure the lead time (average time to complete one item, sometimes
called “cycle time”), optimize the process to make lead time as small and
predictable as possible.
Just In Time (JIT)
WHAT IT IS
• Management philosophy
• “Pull” system though the plant
WHAT IT REQUIRES
• Employee participation
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Industrial engineering/basics
Continuing improvement
Total quality control
Small lot sizes
WHAT IT DOES
• Attacks waste
• Exposes problems and bottlenecks
• Achieves streamlined production
WHAT IT ASSUMES
• Stable environment
7 Types of Waste
• Transportation
• Inventory
• Motion
• Waiting
• Over-processing
• Over-production
• Defects
Poka Yoke
• The process of Zero Defects is also known as “Mistake Proofing” or
“Fail-Safe” or “Error-proofing”.
• Inexpensive
• Very effective
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Bill of Materials (BOM)
CRM
DRP
EOQ
EDI
ERP
FMEA
FIFO & LIFO
GRN
GUS Classification
Kitting
Lead time
Lean manufacturing
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MRP I
MRP II
OEE
Pareto Principle
PDCA
QFD
RFID
Reverse Auction
Reverse logistics
Six sigma
TOC
VMI
WIP