Japanese Lean Words
The A3
More Japanese Lean Words
The New and the Old
Hodge Podge
100
A Japanese word that essentially means “change for the better” or “good change”.
What is Kaizen?
100
A problem solving methodology that focuses on resolving the underlying problem instead of applying quick fixes that only treat immediate symptoms of the problem. A common approach is to ask why five times – each time moving a step closer to discovering the true underlying problem.
What is Root Cause Analysis?
100
In Japanese means “waste”. Anything in the manufacturing process that does not add value from the customer’s perspective.
What is Muda?
100
One of the most powerful but least used lean tools. By documenting the current best practice, this forms the baseline for kaizen or continuous improvement. As this is improved, the new standard becomes the baseline for further improvements, and so on. Improving this is a never-ending process.
What is Standardized Work?
100
Balancing the workload so that there is consistency during the period (day, week, month...). Avoiding spikes in workload has numerous benefits and is tied systemically to other components of lean such as takt time, one piece flow and just in time.
What is Level Loading?
200
Leveling the Workload. The idea that, although customer demand may be variable, all of our processes should deliver consistent quantities of work over time (day to day, hour to hour).
What is Heijunka?
200
A thought process by which the question “why” is asked repeatedly to get to the root cause of a problem. For example -- Why did it occur? Why wasn’t it detected? Why didn’t it get predicted?
What is Five Why's?
200
A Japanese term that means “mistake proofing”. It employs visual signals that make mistakes clearly stand out from the rest, or devices that stop an process if a step is missed.
What is Poka Yoke?
200
A production model in which items are created to meet demand, not created in surplus or in advance of need. The purpose of this is to avoid the waste associated with overproduction, waiting and excess inventory.
What is JIT (Just in Time)?
200
Sort, Set in Order, Shine, Standardize and Sustain. A five step methodology aimed at creating and maintaining an organized visual workplace. This system aids in organizing, cleaning, developing and sustaining a productive work environment.
What is 5S?
300
A Japanese term that means “making visible” and sometimes translated as “visualization”. In addition to presenting problems and plans in an easily understandable visual form, the concept includes the goal of greater transparency and information sharing among employees and/or stakeholders in order to increase the organization's effectiveness.
What is Mieruka?
300
A problem solving approach–built around PDCA using a 11x17 piece of paper (supposedly the largest size that could be faxed) to report problems and improvement suggestions to management. It is used for any kind of problem in all parts of the business to summarize the problem and solution using a way of structuring thinking.
What is A3?
300
A scheduling system for lean and just-in-time (JIT) production by using a visual signal that’s used to trigger an action. This word in Japanese is roughly translated to mean “card you can see.”
What is Kanban?
300
The rate at which products or services should be produced to meet the customer demand. It is derived from a German word which is often referred to as the heartbeat or drumbeat of production in Lean Manufacturing.
What is Takt Time?
300
Specific, Measurable, Attainable, Relevant, and Time-Specific.
What are SMART goals?
400
In Japanese means “automation”. Design equipment and tools to partially automate the process and to automatically stop or warn when defects are detected.
What is Jidoka?
400
It is an iterative four-step management method used in business for the control and continuous improvement of processes and products.
What is PDCA (Plan, Do, Check, Act/Adjust)?
400
In Japanese means "across everywhere." In the lean system, it is used to mean "best practice sharing." In short, it is used to talk about the transfer (sharing) of lean knowledge and practices from one operation to another.
What is Yokoten?
400
Metrics designed to track and encourage progress towards critical goals of the organization. This if strongly promoted can be extremely powerful drivers of behavior – so it is important to carefully select these that will drive desired behavior.
What are KPI's (Key Performance Indicator's)?
400
Identify which part of the manufacturing process limits the overall throughput and improve the performance of that part of the process.
What is Bottleneck Analysis?
500
In Japanese means “the real place”. A philosophy that reminds us to get out of our offices and spend time on the operations floor – the place where real action occurs.
What is Gemba?
500
Overproduction, Waiting, Transportation, Inappropriate Processing, Excessive Inventory, Unnecessary Motion, and Defects.
What is Seven Wastes?
500
In Japanese means "policy deployment". Align the goals of the company (Strategy), with the plans of middle management (Tactics) and the work performed on the plant floor (Action).
What is Hoshin Kanri?
500
A tool used to visually map the flow of production. Shows the current and future state of processes in a way that highlights opportunities for improvement.
What is Value Stream Mapping?
500
A system that alerts all associates (from floor members to management) of an abnormal situation (production line down, behind schedule). Usually a light or an electronic board.
What is Andon?
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