8 Wastes
How to remember the 8 wastes?
TIMWOODS
What is the first S?
Sort
What does PDCA stand for?
Plan - Do - Check - Act
Name the S.T.E.P.S.
A Japanese term meaning “change for the better”. Applied to business organizations, it implies continuing improvement involving everyone
Kaizen
Idle time created when material, information, people, or equipment is not ready.
Waiting
What is the last S?
Sustain
Japanese word of which the literal translation is "the real place." where the actual services are provided or where the work is done.
Gemba
Documented procedures for manufacturing that capture best practices (including the time to complete each task). Must be “living” documentation that is easy to change.
Standardized Work
The process of selecting strategies to meet an objective at any level then getting managers and their teams to engage in dialogue to reach agreement on strategies to achieve their goals.
Catch Ball
Worst waste. Making more then what the customer needs right now.
Over Production
Name the S:
Everything has a place. Visually identify where materials, tools and equipment should be placed.
Straighten
A method of regulating the flow of goods both within the factory and with outside suppliers and customers. Based on automatic replenishment through signal cards that indicate when more goods are needed.
Kanban
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.
Root Cause Analysis
Design error detection and prevention into production processes with the goal of achieving zero defects.
Poka-Yoke (Error Proofing)
What is motion waste?
Movement of people that does not add value (bending, reaching, searching, etc.)
What 5S isn't?
The pace of production (e.g. manufacturing one piece every 34 seconds) that aligns production with customer demand. Calculated as Planned Production Time / Customer Demand.
Takt Time
Visual feedback system for the plant floor that indicates production status, alerts when assistance is needed, and empowers operators to stop the production process.
Andon
Principle the no one upstream function or department should produce a good or service until the customer downstream asks for it
Pull
Name the 8 wastes?
Transportation, inventory, motion, waiting, over processing, over production, defects, skills.
What is standardize?
Establish routines to make the first 3 S's a habit. Create standards that are clear, visual and easy to understand.
What is JIT
Just in time - Pull parts through production based on customer demand instead of pushing parts through production based on projected demand.
Production leveling process that attempts to minimize the impact of peaks and valleys in customer demand. It includes level production volume and level production-variety
Heijunka
At a glance rule – abnormalities are obvious
Visual Management