LEAN GLOSSAR

0-9 

3M

• Muda - Waste
• Mura - unevenness
• Muri - overburden

 

5S

• 1. Seiri Arrangement, only necessary things at the working place
• 2. Seiton Systematic orderliness, all parts and tools are assigned
• 3. Seiso Keep thing clean, prevent contamination
• 4. Seiketsu Standardization, maintain the first 3 S
• 5. Shitsuke Self-discipline, striving for perfection and continuous improvement

 

A 

ABC-XYZ Analysis

Evaluation of material consumption in relation to turnover and predictability

 

Andon

Warning light, to visualize operating conditions

 

Availability

= uptime / (uptime + downtime); Quantifies waste due to unavailability/downtime

 

B 

Bullwhip Effect

Oscillation increasing upstream caused by variation in customer demand

 

C 

Chaku Chaku Line

Material loading and start of operation passing by the machine (e.g. cell-operation)

 

D 

Deming Circle

PDCA, an integral part of CIP:

• Plan - Planning of measures and analyzation
• Do - Doing , implementation of measures
• Check - Check effectiveness of measures
• Act - Update standards

 

DoE

Design of Experiments; Finding the optimal combination of machine parameters by using statistical design of experiments

 

E 

Effectivity

"doing the right things"

 

Efficiency

"doing things right"

 

EPEI

Every Part Every Interval; method for determination of the optimum batch size by using cycle time and setup time. It thereby defines the time span, after which a certain product is produced again. Within this interval, a recurrent pattern of products is produced, thus levelling the production

 

ERM

Enterprise Relationship Management

 

ERP

Enterprise Resource Planning

 

External Setup

Setup work that can be performed with the machine is running

 

F 

FIFO

First-in-First-out - the first incoming part is the first outgoing part

 

First Pass Yield

= (total parts produced - parts of rework - rejects) / total parts produced; Quantifies waste due to deficiency in quality

 

Flow Rate

ratio of process time (cycle time) to the total lead time

 

FMEA

Failure Mode and Effects Analysis; preventive action to analyze the

• probability of the occurence of a certain failure
• meaning and importance to the customer
• detectability of a specific deviation or failure before delivery

 

G 

Gemba

"the real place" where value is created, shopfloor

 

H 

Hancho

Team leader, lowest Management level

 

Hane-dashi

Automatic unloading of parts after they have been processed

 

Heijunka

Sequencing and leveling of the production. A well known tool for planning and visualizing this is the Heijunka box

 

Hoshin Kanri

Policy deployment, breaking down superior targets into more detailed and specific subordinate targets

 

I 

Internal Setup

Setup work that can only be performed with the machine stopped

 

Ishikawa-Diagram

Cause and effect diagram; shows possible causes resulting in or influencing certain effects (also called fishbone diagram or 5-M-Method)

 

J 

Jidoka

Auto-no-mation, autonomous automation, automatic detection of defects, faults and deviations including the automatic stop of operation in case certain limitations are exceeded (failure-proof system)

 

JIS

Just-in-Sequence; in addition to JIT requirements the supplier is also delivering the parts in the ordered sequence

 

JIT

Just-in-Time; having the right parts delivered to the right location, at the right time and in the right quality

 

K 

Kaikaku

Radical holistic LEAN transformation

 

Kaizen

Continuous improvement Process, also known as CIP

 

Kanban

Order card for demand driven production. When a specified reorder limit is reached additional deliveries are triggered. This self-controlling system is often used to realize a pull system. The electronic form of this system is often referred to as eKanban

 

L 

LCA

Low-Cost-Automation; simple low budget automation, often specifically build to simplify and/or automate a certain operation or process. Sometimes with a build-in failure detection

 

M 

Machine Cycle Time

Time for loading, processing and unloading a product

 

Mizusumashi

Logistic expert to reduce the work load of e.g. assembly workers by supplying the material

 

MRP

Material Requirement Planning

 

Muda

Waste, non-value-adding-work, e.g. waiting time, transportation, unnecessary movements, etc.

 

Mura

Abnormalities, unnecessary oscillation and variation

 

Muri

Overload

 

N 

Non Value Adding

every activity, which, from the customer’s point of view, does not create any value

 

O 

OEE

Overall Equipment Effectiveness, Overall availability of the machine based on unexpected downtimes, losses in performance and losses in quality

 

One-Piece Flow

minimum batch size (ideally one single unit) supports the flow and reduces lead time significantly

 

P 

Pareto Principle

Statistical phenomenon: e.g. 80% of the yield are realized with 20% of the total efforts, e.g. 20% of all defect types are causing 80% of the problems in total... (rule of thumb)

 

Poka-Yoke

foolproof system, often a simple mechanism to avoid 100% of the unintentional failures/defects

 

Policy Deployment

Systematic approach to break down the company’s overall targets to more specific operational targets in several steps. Requires a clear strategic direction (jap.: Hohsin) and a master plan (jap.: Kanri)

 

Pull Principle

Demand-driven production; material supply is controlled by the actual consumption, thus reducing inventories and their related costs. No production without customer order

 

Push Principle

Parts and products are pushed through the production, often without any control mechanism or communication and disregarding the actual demand

 

Q 

QFD

Quality Function Deployment is a method of quality management. The main target is to focus on what the customer really wants throughout development, production and sales of a product or service

 

Qualification Matrix

Overview reflecting the qualification level of the employees in respect to different relevant processes. Legs in qualification come to light and can be solved

 

S 

Sequencing

Defining a specific product mix and sequence, to make the variant-specific cycle times compatible with the fixed takt time. This allows some cycle times to exceed the takt time, while the average cycle time remains below the takt time.

 

SMED

Single-Minute-Exchange of Die, single digit setup time (less than ten minutes

 

SOP

Standard Operating Procedure, Standards and detailed descriptions on how to perform a certain procedure or process

 

SPC

Statistical Process Control is a method for controlling production and service processes. Therefore, certain warning and intervention thresholds are determined, using statistical methods

 

T 

Trade-off

A generally positive effect (e.g. savings) with negative side-effects that nullify or even reverse the initially positive effect