LEAN TERMINOLOGY

LEAN TERMINOLOGY

Anything that takes time, resources or space but doesn’t add to the
value of the product or service delivered to the customer.

Any activity in your process that does not add value. MUDA is not
creating value for the customer. In short: WASTE

Type I muda: Non-value-added tasks which seam to be essential.

Business conditions need to be changed to eliminate this type of
waste.
Type II muda: Non-value-added tasks which can be eliminated
immediately.
LEAN TERMINOLOGY

Any variation leading to unbalanced situations. In short:

UNEVENNESS, inconsistent, irregular.

Mura exists when workflow is out of balance and workload

is inconsistent and not incompliance with the standard.
LEAN TERMINOLOGY

Any activity asking unreasonable stress or effort from

personnel, material or equipment. In short:
OVERBURDEN
For people, Muri means: a too heavy mental- or physical
burden.
For machinery Muri means: expecting a machine to do
more than it is capable of- or has been designed to do.
LEAN TERMINOLOGY
LEAN TERMINOLOGY

• One of the two main pillars of TPS.

It refers to the manufacturing and conveyance of only

“what is needed, when it is needed, and in the amount
needed”.
Just-in-time (JIT) manufacturing is a production
model in which items are created to meet customer
demand, not created in surplus or in advance of need.
The purpose of JIT production is to avoid the
waste associated with overproduction, waiting and
excess inventory.
LEAN TERMINOLOGY

• One of the two main pillars of TPS.

It refers to the manufacturing and conveyance of only

“what is needed, when it is needed, and in the amount
needed”.
Just-in-time (JIT) manufacturing is a production
model in which items are created to meet customer
demand, not created in surplus or in advance of need.
The purpose of JIT production is to avoid the
waste associated with overproduction, waiting and
excess inventory.
LEAN TERMINOLOGY

• One of the two main pillars of TPS.

What does Jidoka mean?

A common answer to this question is
"autonomation" or "automation with a human touch."
(Intelligent Automation)
This is usually illustrated by example of a machine
that will detect a problem and stop production
automatically rather than continue to run and produce bad
output. Makes it possible to “build” quality at the
production process.
It help to prevent passing defects and equipment
breakdown.
LEAN TERMINOLOGY

• One of the two main pillars of TPS.

What does Jidoka mean?

A common answer to this question is
"autonomation" or "automation with a human touch."
(Intelligent Automation)
This is usually illustrated by example of a machine
that will detect a problem and stop production
automatically rather than continue to run and produce bad
output. Makes it possible to “build” quality at the
production process.
It help to prevent passing defects and equipment
breakdown.
LEAN TERMINOLOGY

“Ability to understand the status of a production area in

five minutes or less by simple observation without use
of computers, or speaking to anyone.”
LEAN TERMINOLOGY

Is a system of visual and audio devices that distinguish

and communicate promptly between normal and
abnormal conditions.

Is a system of visual and audio devices that identify

abnormal conditions, and modify human behavior to
help all conditions to be in normality.
LEAN TERMINOLOGY

Andon is derived from a Japanese term for a type of

paper lantern.
In manufacturing, Andon systems provide visual
feedback to the plant floor. Typically, Andon systems
indicate line status, show when assistance is needed (e.g.
supervisor or maintenance calls).
It is one of the main tools of Jidoka.
LEAN TERMINOLOGY

Andon is derived from a Japanese term for a type of

paper lantern.
In manufacturing, Andon systems provide visual
feedback to the plant floor. Typically, Andon systems
indicate line status, show when assistance is needed (e.g.
supervisor or maintenance calls).
It is one of the main tools of Jidoka.
LEAN TERMINOLOGY

Quality management concept developed by a

Shigeo Shingo to prevent human errors from occurring in
the production line.
Poka yoke comes from two Japanese words –
“yokeru” which means “to avoid”, and “poka” which means
“inadvertent errors.” Thus, poka yoke more or less
translates to “avoiding inadvertent errors”.
An inexpensive poka yoke device prevents or
eliminates the possibility of a human error from affecting a
machine or process; prevents operator mistakes or errors
from becoming defects.
LEAN TERMINOLOGY

A small sign that is the key control for the Just-In-Time

production; it serves as:
1. Instruction for production and conveyance
2. Visual control tool to check for over production
and to detect irregular processing speeds
3. Tool to perform kaizen

There are two types; production and withdrawal.

LEAN TERMINOLOGY

QCO is a system for reducing setup or changeover time.

This allows organizations to produce smaller batch sizes,
with the ultimate goal of one-piece flow.
LEAN TERMINOLOGY

Proper equipment maintenance is a key to lean

manufacturing success.
TPM (Total Productive Maintenance) is an excellent
method for meeting the demands continuous flow
manufacturing places on equipment focusing for Losses.
An integrated set of activities aimed at maximizing
equipment effectiveness by involving everyone in all
departments at all levels, typically, through small group
activities.
LEAN TERMINOLOGY

A four-step systematic problem-solving iterative

technique used to improve business processes.
The four steps are
Plan
Do
Check
Act
The PDCA Cycle can be used to effect both major
performance breakthroughs as well as small incremental
improvements in projects and processes.
Also known as the Deming cycle.
LEAN TERMINOLOGY

The Toyota Production System organizes all jobs

around human motion and creates an efficient production
sequence without any "Muda."
By documenting the current agreed best practice,
standardized work forms the baseline for kaizen or
continuous improvement.
It consists of three elements:
Takt-Time/Cycle Time
Working Sequence
Standard Work In-Process (WIP)
LEAN TERMINOLOGY

The 5 Whys is a simple problem-solving technique

that helps you to get to the root of a problem quickly.
The 5-Why analysis method is used to move past
symptoms and understand the true root cause of a problem.

It is said that only by asking "Why?" five times,

successively, can you delve into a problem deeply enough
to understand the ultimate root cause. By the time you get to
the 4th or 5th why, you will likely be looking squarely at
management practices.
LEAN TERMINOLOGY

ISQ means never letting a defect pass into the next

station.
Quality at the source – YOU are the source.

It’s mean,
Never Accept
Never Make
Never Pass
LEAN TERMINOLOGY

Gemba is a Japanese term meaning "the real place”.

The real place or the specific place, usually to mean
the shop floor and other areas where work is done or value
is created.

Gemba walks denote

the action of going to see the
actual process, understand
the work, ask questions, and
learn
LEAN TERMINOLOGY

A system of continuous improvement in which

instances of Muda (waste) are eliminated one-by-one at
minimal cost. Focus on incremental improvements.
This is performed by all employees rather than by
specialists.
LEAN TERMINOLOGY

Lean production term which in Japanese means

radical overhaul of an activity to eliminate all waste and
create greater value. Also called breakthrough kaizen.
LEAN TERMINOLOGY

Keeping total manufacturing volume as constant as

possible (production smoothing).
LEAN TERMINOLOGY

FTT as it may sometimes be referred to is a

measure of quality.
It measures how many goods are produced
correctly without flaws or re-work as percentage of total
units produced in a production process or value stream.
LEAN TERMINOLOGY

Sensei is a Japanese word that is literally

translated as "person born before another".
In general usage, it is used, with proper form, after
a person's name, and means "teacher", and the word is
used as to refer to or address teachers.
LEAN TERMINOLOGY