draw the house
go do it!
Level production
heijunka eliminates unevenness in workload (muri) by leveling volumes and enabling easy product switching to produce what is needed when it is needed
house of quality is from…
TPS
kaizen
a strategy where employees at all levels of a company work together proactively to achieve regular, icnremental improvements to the manufacturing process; combines collective talents within a company to create a powerful engine for improvement
produce to demand
takt time is a tool for setting the pace and rhythm of your manufacturing process and aligning it with customer demand; refers to a work-cycle that fulfills customer demand and determines the flow rate to avoid underproduction or overproduction
the five S’s
sort, straighten (organize and keep necessary items in a set, identified locations for ease of use), shine (keep a clean work environment), standardize (establish consistent methods and processes), sustain (stay disciplined)
visible standards
a set of documented procedures and best practices that define the optimal way of performing a task or process; specifies the steps, sequence, timing, and quality standards for each activity, and provides a baseline for continuous improvement
flow or pull
kanban depends on downstream signals to initiate upstream flow; demand-reactive approach minimizes overproducing, lowers what sits waiting, and ensures resources are deployed precisely as needed
Just in Time
a “pull” system that strives to produce only what is needed, in the quantity needed, when needed
seperate man from machine
respect the intelligence of your workforce and focus them on tasks that machines cannot effectively do; applies to the routine, repetitive tasks that can be automated
minimize batch size
single-minute exchange of die is manufacturing technique to reduce inefficiencies; provides a rapid and efficient way to the changeover process, key to reducing production lot sizes, reducing uneven flow, production loss, and output variability
benefits of VOP
process understanding, identifying variability, continuous improvement, data-driven decisions, root cause analysis, quality management, cost reduction, performance metrics, risk management (pro identifying connor dating rare queens, costing performance risk)
jidoka
automation with a human touch, concept in lean manufacturing that involves stopping machines automatically when problems arise; improve quality and efficiency while reducing waste
stop and make
andon, a visual management system that alerts workers to problems in manufacturing
prevent errors
poka-yoke, frequently used in lean systems to help workers avoid making mistakes (mistake proofing signals)
pareto charts
bar charts, sorted from largest to smallest, that also communicate the cumulative percent represented by the various factors in the chart, based on the 80/20 rule
VOP things to note with VOC
they do not always align perfectly, but VOC can build better VOP
decision symbol
(in process map) diamond
cause and effect diagram
also called ishikawa or fishbone (lowers levels of abstraction in solving problems)
Ishikawa basic sevel tools of quality
process map, flowchart, check sheet, hisogram, scatter plots, control charts, cause and effect diagrams, pareto anaylsis
page connector symbol
(in process map) circle
processing symbol
(in process map) rectangle
start/stop symbol
(in process map) thin rectangle
check sheets (+steps)
data gathering tools that can be used to provide data for histograms; identify common defects, draw a table with common defects (problem type-column and time period-top), user places check marks on the sheet whenever the defect is encountered
