Glossary of Terms

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  • 3 General Principles of Kaizen
    The key to successful Kaizen is going to the shop floor, working with the actual product, and getting the facts. The three principles of Kaizen are: gemba: the shop floor gembutsu: the actual(...) - Read More
  • 3Ds (3 elements of demand)
    Working conditions or jobs that are dirty, dangerous or difficult. - Read More
  • 3P (Production Preparation Process)
    Rapidly designing production processes and equipment to ensure capability, built-in quality, productivity and takt-flow-pull. The production preparation process minimizes resources needed such as(...) - Read More
  • 3 Drivers of Customer Satisfaction
    The three drivers of customer satisfaction are quality, cost and delivery. - Read More
  • 5 Steps for Lean
    Define value as perceived by the customer Identify the value stream and eliminate waste Make your product or service ‘flow’ through the value stream ‘Pull’ your product or service(...) - Read More
  • 5 Whys
    A simple but effective method of analyzing and solving problems by asking “why” five times (or as many times as needed to determine root cause). This approach is used to construct cause-and-effect(...) - Read More
  • 5S
    A method for organizing a workplace, especially a shared workplace (like a shop floor or an office area), and keeping it organized. The 5Ss are used to eliminate waste and increase efficiency. Some(...) - Read More
  • 6Ms of Production (man, machine, material, method, mother nature and measurement)
    Understanding how these factors impact the process and the establishment of standards are key steps in strengthening production processes. These factors are used to construct cause-and-effect diagrams. - Read More
  • 6 Big Losses in Equipment Efficiency
    One of the major goals of TPM (Total Productive Maintenance) and OEE (Operating Equipment Effectiveness) focused programs is to reduce and / or eliminate what are called the Six Big Losses — the most(...) - Read More
  • 7 Tools of QC
    Presents complex or abstract statistical information in a simple, visual format. The seven quality tools help monitor and control production processes, analyze and solve problems, generate ideas, and(...) - Read More
  • 7 Management and Planning Tools
    The seven management and planning tools have their roots in operations research work done after World War II and in Japanese Total Quality Control (TQC) research. In 1979, the book Seven New Quality(...) - Read More
  • 7 Leadership Wastes
    Arise from a failure of leadership to harness the potential that resides in all workgroups. The seven wastes of leadership are: focus waste: Arises when everyone is not aligned and energized on(...) - Read More
  • 7 Types of Waste
    Classification of the seven types of waste in production systems, as defined by Taiichi Ohno, the father of waste elimination in manufacturing operations, are as follows. Waste is defined as anything(...) - Read More
  • 7 Characteristics of a Business Process
    A process is a series of actions or steps toward achieving a particular end. A business process or a sub-process can be described based on the following characteristics: scope: Starting point(...) - Read More
  • 20 Keys
    The 20 Keys is an intuitive system of improvement that breaks a function or work area (like manufacturing or sales or materials management) into 20 “key” elements. The approach focuses each workgroup(...) - Read More
  • 100% Inspection
    Lean emphasizes “zero defects” by preventing errors or problems from becoming defects in the product. The term "100% inspection" in Lean refers to more than having an operator conduct an inspection(...) - Read More
  • A3 Process
    A3 is metric nomenclature for a paper size document. Toyota believes that when you structure your problem-solving around a 1-page piece of paper, then your thinking is focused and structured as(...) - Read More
  • ABC Inventory Classification
    Inventory in any organization can run in thousands of part numbers or classifications, as well as millions of parts in quantity. Therefore, inventory is required to be classified with some logic to(...) - Read More
  • Abnormal Management
    Being able to see and quickly take action to correct abnormalities (i.e., any straying from Standard Work). This is the goal of standardization and visual management. Continuous waste elimination and(...) - Read More
  • Activity Network Diagram
    See 7MP Tools - Read More
  • Activity-Based Costing
    A management accounting system that assigns cost to products based on the resources used to perform the applicable processes (e.g., design, order entry, production, etc.). These resources include(...) - Read More
  • Actual Person-Hours
    One person-hour = 60 minutes of available work time. The sum of person-hours (i.e., actual number of operations multiplied by actual hours worked per operator) used to produce a set number of units. - Read More
  • Affinity Diagram
    See 7MP Tools - Read More
  • Andon
    A visual control device typically leveraged in production areas that utilize a lighted overhead display or board. Andons are used to give the current status of the production system and alert team(...) - Read More
  • As Is
    A representation or description of a current state (e.g., an organization, a process, etc.). - Read More
  • Back Flush
    The process of automatically reducing perpetual inventory records, based on the bill of materials of a given product. Normally triggered by shipment and invoicing to a customer, back flushing is used(...) - Read More
  • Batch Production
    Batch production is the practice of making parts in large lots and accumulating them in batches before they are released to the next stage of production. In contrast to Single Piece Flow, batches are(...) - Read More
  • Benchmark
    A benchmark is a standard of performance against which similar or comparable products, processes or methods are measured or judged. - Read More
  • Bottleneck
    A bottleneck is a phenomenon where the performance or capacity of an entire system is limited by a single component or function. The component or function is sometimes called a bottleneck point. The(...) - Read More
  • Buffer Stock
    Inventory used to mitigate or "level" fluctuations in customer demand. - Read More
  • Capability (or Process Capability, or Cpk)
    The level of ability involved with a process to perform as expected. Often referred to as Cpk, this reflects how well a process can be performed and delivered defect free. The Cpk is compared to(...) - Read More
  • Cellular Manufacturing
    Operating units (or 'cells') in which equipment and workstations are arranged to facilitate small lot, continuous flow production. Typically involves grouping complementary operations to facilitate(...) - Read More
  • Changeovers
    Changeovers are the time between the last good piece of one run to the first good piece of the next run. Changeover time is down time, so quick changeovers effectively reduce waste. - Read More
  • Continuous Flow
    Continuous Flow is the optimal state of production in which goods are made according to the rate of customer demand, i.e., producing exactly what is needed, when it is needed, and in the quantities(...) - Read More
  • Continuous Improvement
    Continuous Improvement is the never-ending commitment to improving overall business operations by involving employees and applying proven techniques to reduce waste and increase process efficiency. - Read More
  • Cost of Quality
    Cost of Quality is the quantification of costs associated with defects incurred in production, e.g., internal and external failures, appraisal, and prevention costs. - Read More
  • Cross Training
    Cross Training is a skills development practice that enables workers to master multiple job skills and increase operational flexibility. Also known as skills versatility. - Read More
  • Cross-functional Team
    A Cross-functional Team is a team of people from different areas and functions working together to solve a specific problem or perform a specific task. - Read More
  • Daily Huddles (or Daily Workgroup Meetings)
    See Lean Daily Management System® - Read More
  • Daily Management
    Attention each day to those issues concerned with the normal operation of a business. - Read More
  • Effectiveness
    A general term used to describe an activity or process’s ability to meet the needs of the customer. An effective process successfully achieves planned outcomes in a planned manner (e.g., on time,(...) - Read More
  • Error-proofing
    Error-proofing is the process of anticipating, detecting and preventing errors that adversely affect product quality, process efficiency and customer satisfaction. It focuses on preventing errors or(...) - Read More
  • Executive Steering Committee (ESC)
    The Executive Steering Committee (ESC) engages leadership to compel sustainable implementation results that improve enterprise performance. It’s composed of committed top leaders who are accountable(...) - Read More
  • Facilitation
    Concerns itself with all the tasks needed to run a productive and impartial meeting or event. Facilitation serves the needs of any group that is meeting with a common purpose, whether it be making a(...) - Read More
  • Flow
    Flow is the progressive completion of tasks in the value chain to deliver products and services that meet customer requirements. Optimal flow means material / information moves through the entire(...) - Read More
  • Gantt Chart
    A type of chart that displays all of the action items for a project, along with timelines and names of people responsible for each item. - Read More
  • Hand-Off
    The transfer of material or information to the next step in a process. Too many, or poorly executed, hand-offs can be a major source of waste. - Read More
  • IDOV
    Another popular, structured step-by-step approach to Six Sigma as applied to design (referred to as design for Six Sigma or DFSS). The four basic steps of the methodology are: Identify the(...) - Read More
  • Inventory Management
    Inventory management consists of all the activities that improve the flow of material within an operation by minimizing inventories. It relies heavily on logistics management and Just In Time systems(...) - Read More
  • jidoka
    See Autonomation - Read More
  • Just In Time
    Just In Time (JIT) is a technique for producing and delivering customer requirements when they are needed to minimize the accumulation of inventories. - Read More
  • Kaizen
    A Japanese term meaning "small, continuous improvement on everyone’s part." The word itself comes from the Japanese words “kai” (small, little, good) and “zen” (good, change for the better). The(...) - Read More
  • Kaizen Action Sheet (KAS) System
    A Kaizen Action Sheet (KAS) is a single sheet of paper that provides a way for an individual to suggest process improvements within their work area. The document is simple. It asks for a description(...) - Read More
  • Kaizen Event
    A Kaizen Event is a facilitated standard workshop that uses a team to improve process related problems. Originating in Japan in the 1970s, the Kaizen Event is designed to help teams solve process(...) - Read More
  • Kanban
    A kanban is an overt signal such as cards, printed labels or electric signals within production processes that trigger the release of materials from 'upstream' to 'downstream' workstations. Kanbans(...) - Read More
  • Lead Time
    The time it takes from receipt of an order until the finished product is ready for use. - Read More
  • Lean
    Lean Definition Short Answer: Lean is the fervent elimination of waste. Long Answer: Lean is a leadership approach AND a management philosophy AND a set of tactical methods that, as a(...) - Read More
  • Lean Daily Management System
    The Lean Daily Management System (LDMS) is a set of standard procedures that provides the structure and focus for intact workgroups with common tasks and deliverables to continuously improve their(...) - Read More
  • Lean Leadership
    Lean Leadership a way of work that emphasizes performance improvement, change and managing resistance to uncertainty. Lean leaders excel in two areas: setting direction aimed at incremental(...) - Read More
  • Leveling
    Leveling is a technique for producing a controlled amount of supply to meet planned requirements despite fluctuations in demand. - Read More
  • LIFO
    LIFO is the acronym for last in, first out. It is an asset management method that moves the costs of products from inventory to the cost of goods sold. Under LIFO the latest or more recent costs of(...) - Read More
  • Macro Process
    The name given to a group of micro processes, such as processing a purchase order or annual planning. - Read More
  • Mass Production
    Mass production is an economic principle that assumes production efficiency is achieved when goods are standardized, made in large volumes and manufactured at the highest speeds possible. Mass(...) - Read More
  • Milk Run
    A milk run is the use of single delivery vehicles for multiple pickups or deliveries rather than multiple vehicles for single purpose pickups or deliveries. - Read More
  • Muda
    Muda is the Japanese term for 'waste,' now commonly used to define the kinds of inefficiencies that exist in typical business operations. While many organizations consider there to be eight kinds of(...) - Read More
  • nagara
    Japanese term for "while doing something, accomplishing more than one task in one motion or function." - Read More
  • Natural Work Group
    A Natural Work Group, or Intact Work Group, is a team of workers who share a common workplace and have responsibility for a common process or product. - Read More
  • Office Kaizen
    Office Kaizen (Lean Office) adapts proven Lean methods for practical relevance within functional, administrative and service delivery settings. It consolidates and applies best practices from kaizen,(...) - Read More
  • Pareto Chart
    A vertical bar graph showing the bars in descending order of significance, ordered from left to right. It helps to focus on the vital few issues, rather than the trivial many. An extension of the(...) - Read More
  • Primary Visual Display
    A primary visual display (PVD) is a large visual display that presents the current status of intact workgroup on key metrics, goals, objectives and action plans. It is a core component of Kaufman(...) - Read More
  • Procedural Adherence
    Procedural Adherence: Aligned values for explicit behaviors that demonstrate the highest regard for follow established standards that minimize risk. Procedures are the sequence of events that(...) - Read More
  • Quality
    A business discipline that focuses on meeting customer specifications and requirements. Quality is synonymous with the ability to meet customer requirements all the time. - Read More
  • RACI (Responsible, Accountable, Consult, Inform) Matrix
    A planning tool used to identify and clarify roles, responsibilities and individual levels of participation across all functions (activities, tasks and decisions) to ensure effective operation. - Read More
  • Rapid Improvement Event (RIE)
    The Rapid Improvement Event (RIE) is a standard approach to team-based problem solving. The RIE helps teams focus on process problems that are beyond the day-to-day work and is a fundamental and(...) - Read More
  • sensei (or Lean sensei)
    An outside master or teacher that assists in implementing Lean practices. - Read More
  • Short Interval Coaching (SIC)
    Short Interval Coaching (SIC) as its name implies, is frequent standard coaching sessions at “short intervals.” The practice originates from an understanding that supervisors and managers often get(...) - Read More
  • Six Sigma
    Six Sigma is a structured problem-solving, process improvement and quality management methodology composed of scores of integrated tools and techniques. Trained and validated practitioners use(...) - Read More
  • SLIM-IT
    SLIM-IT® is a project implementation and management framework. It works because it literally surrounds process improvement tools and activities with human factors as part of its structure. Most(...) - Read More
  • Standard Work
    Standard Work is the documented, single best repeatable practice to perform a process as designed by the people who do the work. Implicit with this definition is the notion that the people (when(...) - Read More
  • takt time
    The available time over the customer demand. The term Takt is German and refers to cadence, rhythm or tempo. For example, if customers demand 240 widgets and the factory operates 480 minutes per day,(...) - Read More
  • Throughput
    Rate of production — of a defined process — over a stated period of time. Throughput is calculated as units produced divided by a period of time. - Read More
  • Throughput Time
    The elapsed time required for a product to go through a defined process, from beginning to end, including both processing time and queue time / lead time. Throughput time for a process is synonymous(...) - Read More
  • Total Productive Maintenance
    Total Productive Maintenance (TPM) is a series of methods to ensure that every machine in a production process is always able to perform its required tasks through improved equipment availability /(...) - Read More
  • Toyota Production System (TPS)
    The philosophy which organizes manufacturing and logistics at Toyota, including the interaction with suppliers and customers. The TPS is a major part of the more generic "Lean manufacturing.” The(...) - Read More
  • Tree Diagram
    A tree diagram breaks down broad categories into finer levels of detail. It can map levels of details of tasks that are required to accomplish a goal or activity. Developing the tree diagram helps(...) - Read More
  • Upstream Process
    Any work unit or operation in a business process that supplies goods or services to another (downstream) unit. - Read More
  • Value
    A capability provided to a customer at the right time and at an appropriate price — as defined in each case by the customer. - Read More
  • Value Chain
    Any activity outside an organization that adds value to your final product, such as the value-adding activities of your suppliers. - Read More
  • Value Stream
    The specific activities required to design, order, and provide a specific product, from concept to launch, order to delivery and / or raw materials into the hands of the customer. - Read More
  • Value Stream Mapping
    A structured process mapping technique that focuses on locating and assessing hands-on work time (i.e., cycle time) and waiting (i.e., lead) time, as well as other elements of interest. Process(...) - Read More
  • Value Stream Owner / Manager
    Person responsible for creating a future state value stream map and leading complete implementation of the future state for a process or a product across departmental and functional boundaries. - Read More
  • Value-Added
    Any task or process that transforms or adds value to a product or service to meet customer requirements. It is an essential part of any business process and is what the customer is willing to pay for. - Read More
  • Value-Added Analysis
    An improvement team strips a process down to its essential elements. The team isolates the activities that, in the eyes of the customer, actually add value to the product or service. The remaining(...) - Read More
  • Value-Adding Activity / Process
    Any activity that transforms materials or information into a usable product or service that the customer is willing to pay for. - Read More
  • Variation
    The degree to which actual results are different from an established standard or specification. Variation can occur within a process or any characteristic of a product /  service and is the primary(...) - Read More
  • Vertical Teams
    See Cross-Functional Team - Read More
  • Vision
    A bold, long-range goal, or an ideal image of the future — and an imaginative picture of what can be accomplished. Characteristics of a shared vision include: Desirable and rewarding (...) - Read More
  • Vision Control
    Any visual indicator of actual performance versus expected performance in the workplace. Examples include correct tool placement, tracking production run data or signaling that a piece of equipment(...) - Read More
  • Visual Factory
    An environment in which every worker can see the same thing, at the same time. Everyone knows exactly what they should be working on to move the organization forward. Some techniques include: (...) - Read More
  • Visual System
    An approach in which the condition and status of every relevant element of a work environment, as well as critical needed actions, is openly displayed and updated so that everyone knows what to do,(...) - Read More
  • Voice of the Customer (VOC)
    Desires and requirements of the customer at all levels that are translated into real terms for consideration in the development of new products, services and daily business conduct. - Read More
  • waste (or muda)
    See 7 Types of Waste - Read More
  • Work in Process (or Work in Progress or WIP)
    A measure of the quantity of goods in various stages of completion throughout the facility, from raw materials to completed products. WIP disrupts single-piece flow and anything that is not(...) - Read More
  • Work Sequence
    The specific order in which an operator performs the manual steps of the process. - Read More
  • Work Unit
    A team of employees that share a common work area and have responsibility for a particular process or product. - Read More
  • Work Unit Metrics
    A set of measurement indicators used to track work unit performance on a day-to-day basis. Examples include productivity (versus plan), defects, skill versatility, safety and absenteeism. Work unit(...) - Read More
  • Workplace Organization (WPO)
    The discipline of configuring workspaces to optimize material flow by minimizing the consumption of distance, time and space. - Read More
  • Workstation Optimization
    Design the work area for operator movement as opposed to storing material and supplies. Achieve the optimum work area that minimizes operator motions and facilitates safe, efficient work. - Read More
  • World-Class Quality Management
    A quality management system that is the benchmark for other industries and competitors. See Quality Management. - Read More
  • Yield
    See First Pass Quality or First Pass Yield - Read More