Real Bones Poka Yoke Examples In Production

The following contains a sometimes commented glossary of terms related to lean manufacturing or production management with a brief definition.

The list includes a lot of Japanese terms, although almost all of them can also easily be explained using English terms, which are also given.

This list is ever expanding but never complete, as the tendency to invent new terms or buzzwords outstrips the ability of any lexicographer. While a lot of the terms below are useful, many of them seem to have been invented solely to sell more products and services to industry using fancy buzzwords. To make things easier for you I have marked which terms are in my opinion more or less relevant: Please let me know if you think there are any terms missing.

A full bullet indicates a more relevant term. Those will help you in your daily Lean related work. A circle bullet indicates a less relevant term. Those are less useful to me, but can be used to bedazzle others with fancy language, or to avoid being bedazzled by others. Short for the words Muda wasteMura unevennessand Muri overburden. However, I think you are perfectly fine with sticking to the original 3M.

Product design process developed initially at Volkswagen focusing in manufacturability. One of its key features is the use of models or prototypes for assembly tests.

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Sometimes one of these 3R is swapped with Genchi for the real place or Genchi Genbutsu for going and seeing the real place. Common structure for potential causes for Problem Solving methods, for example as the bones of the Fish Bone Diagram. This is often expanded into 8M, including additionally management, milieu, measurement, and money. Otherwise everything else is the same. See 5 S for more. In English also sometimes translated into 5 C.

Originally a quality based approach to manufacturing, requiring six standard deviations actually 4. Has by now expanded to include all of lean manufacturing and is hence often called Lean Six Sigma. Six Sigma is well known for its lean training organization awarding green belts and Black Beltsalthough a black belt does not automatically mean that the person has experience in lean.

See also my post on Six Sigma. Traditionally, waste Muda is grouped into seven types. The seven types of waste commonly used in lean are in the original sequence of Ohno starting with the worst overproduction, waiting of operatorsunnecessary transport, over-processing, inventory, movement of operatorsand defects and rework. Many more types of waste have been added in the western world, most prominently wasted human creativity — although I am a fan of the original seven types from Toyota.

See Tim Wood for an easy to remember mnemonic, although the sequence is not in t he original priority. Method developed at Ford in for Problem Solving based on eight disciplines, although a ninth discipline Number 0 has later been added.

The disciplines in order are: List of aspects that have to be right in supply chain management or purchasing.

The exact content of the list varies, as there are also examples with 5R.

Usually it includes the right quality, right quantity, right material type, right place, right time, right source, right price, right type of transport, right contract. The first five of these are usually the 5R, pick any of the nine in the list for the other 8R, as not everybody agrees on what is right.

Base your decision on long-term philosophy rather than short term goals; 3: Use pull to avoid overproduction; 4: Level the workload; 7: Use visual controls; Respect your extended network of partners and suppliers; Become a learning organization.

While believe it is impossible to capture the Toyota production system in a few bullets, I do think he got the significant key points and do like the overview. List of 14 key points developed by W. Edwards Deming to help managers with transforming and improving their business.

Examples would be 1 Create constancy of purpose toward improvement of product and service; 6 Institute training Real Bones Poka Yoke Examples In Production the job; or 10 Eliminate slogans, exhortations, and targets for the work force asking for zero defects and new levels of productivity.

Structured Problem Solving sheet named after the paper format DIN A3, which is small enough to carry around yet large enough to fit all the data. Ideally done by hand, but in the western world mostly done through computer files. Sometimes also called A3 report. See also my series of posts starting with The A3 Report — Part 1: Type of process control, where multiple sequential machines are synchronized. If the subsequent machine B stops, machine A stops, too, even if there would be still space in the buffer Gambling Money Big Ferris Wheels In Vegas between.

Similarly, if the first machine A stops, machine B also stops, even if there are still parts in the buffer in between. The goal is to reduce overproduction even more than with a normal FIFO in between.

Sometimes also called AB control or Full Work control. Sequential ordering of product variants by quantity or value sold. The goal is to distinguish high volume parts from low volume parts. Combination of the ABC Analysis and the XYZ Analysiswhere every part number is categorized in 9 categories, from AX for frequently and in large quantities ordered part types to CZ for infrequent and little ordered part types.

Method to find the Bottleneck in a simulation or data-rich environment. The momentary bottleneck is the process with the longest duration between interruptions by waiting waiting for parts from an upstream process, waiting for a downstream process. Please be aware that the statuses of the machines need to be known at all times for this method to work.

Hence, the method is well suited for simulations, but less suited for reals hop floors. For real shop floors I recommend the Bottleneck Walk. Both methods developed by me. Adaptable manufacturing supposedly considers unforeseen future events during factory planning. Sort of a Brainstorming method that groups ideas.

Philosophy initially for software development, somewhat similar or competing with Lean. It started as a counter-movement to a heavily regulated and inflexible software development approach that was suggested to be used before. Hence the name Agile as a counter-movement to the inflexible and rigid system before.

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Not to be confused with the Agile Manufacturing System. One popular tool is for example Scrum. Similar to good implementations of Lean there is a focus on practical solutions over rigid methods, a focus on working with people, and a focus on value for the customer.

Another difference is that Lean focuses on the production and Agile on the product. Agile would be more for the development of a product, Lean more for the manufacturing of it. Core philosophy of Agile. It is refreshingly brief, hence listed here in full: We are uncovering better ways of developing software by doing it and helping others do it. Through this work we have come to value: That is, while there is value in the items on the right, we value the items on the left more. Agile manufacturing aims for a quick response to changes.

American System of Manufacturing: Set of manufacturing methods that evolved in the 19th century America, first in the Springfield and Harpers Ferry Armories. It includes mechanization and the use of interchangeable parts.

Also known as the American System. It is an improvement of the English system of manufacturingand the precursor of Fordism. The Company is organized in small groups of 5 to 50 people, the Amoebas.

These amoebas have to create profit. If they are successful and grow, they split up. If they are not successful, they are eventually swallowed by other amoebas. The name originates in biology, where Amoeba are single celled organism that split in two if they grow too big. Signboard in manufacturing that shows the current state of the operations including for example parts produced target and current, process breakdowns, etc.

Sometimes also called andon board. Often in combination with Andon Line.

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Line, button, or switch that is pressed to indicate problems at a process. Can be more than one line for minor or serious problems. Sometimes also called Andon Cord. Often in combination with Andon.

Product design method originating from the US automotive industry with the goal to design products that satisfy the customer. A company needs to be clear about where it wants to go before it can achieve its goals. In English often translated as True North or target state. Cell is used in many different and often overlapping contexts in manufacturing e.

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This type of poka-yoke is useful for mass production environments with of examples of poka-yoke of three of poka-yoke systems: preparation poka. Here an example of Poka-Yoke and process improvement. Discover how the Poka-Yoke could really improve the process Lean Production, Real Examples The Ultimate. poke-yoke: mistake proofing like each of the bones on a fish. these include reasons related to people, for example, errors may have.

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