Continuous Process Improvement: Managing Flow 123

assembly

A manufacturing process in which two or more components are joined together to create a finished part. Assembly may include the use of fasteners, adhesives, or welding to attach parts to one another.

batches

A specific number of the same part that moves through the production cycle as a group. Producing small batches allows companies to steadily meet customer demand.

battery management system

BMS. A computer that monitors, regulates, and coordinates the operations of a battery pack. The battery management system helps to prevent overheating and thermal runaway.

bottlenecking

Congestion during the production process. Bottlenecking limits the flow of production.

breakdowns

A malfunction that prevents a component or process from operating correctly. Breakdowns usually result in maintenance expenses and lost productivity.

calibration

The process of adjusting equipment to ensure accuracy to a measurement standard. Regular calibration is essential for maintaining consistency.

changeover

The process of switching a machine from one part setup or process to another. Changeover activities may include cleaning, disassembly, reassembly, and other setup activities.

check sheet

A tool used to collect and record observable data using tally marks. A check sheet is typically simple forms that can be filled out by hand, but it may also be produced by smart technology.

circuit boards

A thin, insulating board that supports electronic components and chips. The circuit board in a battery management system monitors the charge and discharge of a battery pack.

congestion

The state of a workplace that is overcrowded with inventory, equipment, or people. Congestion causes delays and bottlenecking that disrupt the flow of goods.

continuous improvement

An ongoing effort to make products, services, or processes better. Continuous improvement identifies opportunities for improvement, takes action to achieve improvement, analyzes the results, and implements workable solutions.

current state map

A visual tool that documents an existing process. A current state map, sometimes called a present state map, captures all of the details of a process as it exists at the moment the map is produced, including any flaws or errors.

cycle time

The actual time it takes to perform a task and move it to the next step. One of the major goals of lean is to match cycle time to takt time in order to meet the customer's requirements.

data boxes

A value stream mapping icon used to represent numerical information related to a particular process. Data boxes are located directly beneath a process box and contain information such as changeover and cycle time.

defects

An imperfection in a part that prevents it from operating correctly. Defects can lead to reworked or scrapped parts, which increases the costs of a manufacturing operation.

downstream activities

Any task that occurs after other upstream tasks in a process. Downstream activities often include finishing and assembly.

downtime

A period of time when production stops, often due to mechanical failure or maintenance needs. Downtime reduces the efficiency of a manufacturing operation and should always be limited as much as possible.

drive shaft

A long, cylindrical component that transfers power from a motor to other machine components. Drive shafts are used in a variety of applications, such as car engines and metal cutting machines.

economies of scale

The reduction in price per individual product that occurs when large quantities of products are produced. Economies of scale is an advantage of mass production.

efficiency

The ability to produce an intended result in a way that produces the least waste of time, effort, and resources. Ensuring efficiency is a major goal of lean manufacturing.

ekanban

A digital method used to signal production and material movement. Ekanbans, also known as electronic kanbans, include information about inventory levels and part movement.

electronic kanban

A digital method used to signal production and material movement. Electronic kanbans, also known as ekanbans, include information about inventory levels and part movement.

engine

A machine that converts energy into mechanical force and motion. Car engines convert gas, diesel, or electrical energy into mechanical energy.

engineering

The application of science and technology for the purposes of designing, creating, or improving a product or process. Engineering helps manufacturers optimize the design of products to meet customer requirements.

engineering flow

The steps involved in designing quality products and services. Engineering flow moves from part design to the selection of raw materials, then finally to structuring manufacturing processes to create a product or service.

excess inventory

The storage of more materials or parts than necessary. Excess inventory ties up company resources that could be better used elsewhere and takes up space.

finished goods flow

The movement of products that have undergone all necessary manufacturing processes. Finished goods flow involves storing, selling, and distributing products.

finishing

A final machining process that achieves the desired surface finish and tolerance for a part or component. Finishing is usually the last step in the machining process.

floorplan

A two-dimensional drawing that depicts the arrangement of the workplace. Floorplans can be used to plan changes to a work environment to improve flow.

flow

The movement of materials, products, and information through the various steps of a manufacturing process. A consistent flow is essential to eliminating waste and improving efficiency.

forecasting

To predict demand for a product based on previous patterns. Forecasting helps organizations determine the amount of inventory they need, the production schedule, and the cost of manufacturing products.

future state map

A visual tool that shows an ideal version of a process that can be achieved by implementing improvements. A future state map incorporates lean strategies to improve existing processes.

information flow

The movement of information involved in decision-making and manufacturing activities between departments or organizations. Information flow involves maintaining purchase and sales records, production reports, and customer relations information.

injection molding

A molding process in which resin is heated in a barrel and then injected into a mold. Injection molding can produce large items such as car dashboards and smaller items such as packing peanuts.

inspecting

The examination of a part during or after its creation to confirm that it adheres to specifications. Inspecting products allows manufacturers to identify and correct product defects.

intangible

Not physical in nature. Intangible barriers to flow include resistance to change, communication barriers, and a lack of coordination between departments.

inventory

A quantity of goods held in stock. Inventory refers to raw materials, partially finished products, and finished products prior to sale.

invoices

A document issued to a buyer from a supplier as a transaction record. Invoices list the goods provided by the supplier and their costs.

kanban

A visual signal that indicates when more material is needed. Traditional kanban uses signals like cards, while electronic kanban uses bar codes or smart sensors to send information to a computer system.

kanban board

A visual tool that uses cards organized in columns to track the flow and status of different tasks in a process. Kanban board cards are often color-coded by type of work.

laser cutter

A device that generates, focuses, concentrates, and delivers a laser beam to cut into a workpiece. Laser cutting machines are generally faster and more precise than traditional cutting machines.

lean manufacturing

An approach to manufacturing that seeks to reduce the cycle time of processes, increase flexibility, and improve quality. Lean manufacturing helps to eliminate waste in all its forms.

line balancing

The even assignment of work between a number of employees or workstations so that a specific number of tasks can be completed within a specific amount of time. Line balancing helps improve flow and contributes to steady production rates.

linked workcells

A group of connected workcells that work together to manufacture a part in sequential stages. Linked workcells are necessary for the construction of more complex products for which a single process or task is insufficient.

machine flow

The movement of equipment and machines within a workplace. Machine flow involves maintaining and calibrating equipment, as well as arranging equipment within a workspace.

machining

A manufacturing process that involves removing material to form an object. Machining can occur using traditional methods, like turning, drilling, milling, and grinding, or with less traditional methods that use electricity, heat, or chemical reaction.

maintenance

Any activity that contributes to the care and upkeep of machines or equipment. Maintenance approaches can involve monitoring equipment for problems or fixing a machine after it breaks down.

mass production

A production method that creates large batches of a product. Mass production creates large quantities of products at lower costs.

metrics

A measured variable that indicates the performance and status of a process. Metrics can indicate cycle times, defect rates, and other information.

non-value added

Any activity that does not contribute to a product or service and is not essential. Non-value added steps, such as reworking defective products or waiting during production delays, waste company resources and should be eliminated.

non-value added but essential

Any activity that supports value-added activities but that does not directly contribute to a product. Non-value added but essential activities are those that a customer is unwilling to pay for but that are necessary to the manufacturing process, such as material handling, inspection, and retooling.

operator flow

The movement of employees within a workspace. Operator flow involves placing and moving employees between stations in a production line.

overproduction

Creating too many products in anticipation of customer demand. Overproduction leads to the creation of products that may not be used.

part bins

A designated container for storing and transporting small parts and components. Part bins are used to maintain a clean workspace.

plastic

A lightweight polymer material that has high corrosion resistance, a high strength-to-weight ratio, and a low melting point. Most plastics are easily shaped and formed.

powertrain

A series of automotive components that generate and deliver power. Powertrains include an engine, transmission, and other components.

process

The series of activities required to create a product or provide a service to a customer. A process can include many different steps, including manufacturing and administrative tasks.

process boxes

A value stream mapping icon used to represent a single operation. Process boxes are located along the bottom of the value stream map.

process workflow

The series of activities that are necessary to complete a task. A process workflow includes the sequence of industrial, administrative, and other steps necessary to produce a product or provide a service.

product

An item that a company makes or provides for a customer. Products include any goods that result from a process, such as manufactured parts and refined materials.

product workflow

The steps necessary to create a finished product. Product workflow includes processes like obtaining raw materials, machining, and assembly.

production board

A visual tool that shows metrics such as production targets and actual production results. Production boards often contain information such as the production schedule, maintenance tasks, and bottlenecks.

production cycle

The series of steps it takes to convert raw materials into finished products and deliver them to the consumer. The production cycle includes tasks such as product design, assembly, and delivery.

production kanban

A signal that authorizes the supplying work area to produce more of a product. Once a withdrawal kanban has depleted stocked materials or parts, a production kanban is sent to upstream activities to replenish the stock.

production line

An arrangement of employees, equipment, and machinery that allows for manufacturing processes to occur sequentially. The production line is involved in processing raw materials and transforming them into usable parts or products.

pull system

A material management system in which materials and parts are not delivered to the next stage of a process until they are needed. A pull system is characterized by smaller batches, quick responses to customer demand, and smooth product flow.

push systems

A production method in which parts or products are produced based on forecasting customer demand. Push systems often lead to excess inventory.

quality

Conformance to a set of standards or specifications that results in customer satisfaction in a product or service. Quality products are free of defects and meet the requirements of their anticipated use.

quality control

A system of managing quality by inspecting finished products to make sure they meet specifications. Quality control relies on error detection and correction.

raw material flow

The movement of materials from a supplier to a manufacturer, as well as the storage of those materials. Raw material flow involves making sure materials are available at a workstation when they are needed.

raw materials

An unprocessed or lightly processed object or substance used to make a finished part. Raw materials in manufacturing include metal, plastic, and ceramic.

receiving department

The part of an organization responsible for accepting goods from an external supplier. The receiving department handles any incoming purchases and transports them to a point of storage.

rework

The process of running a part through an additional and unplanned manufacturing step. Rework is necessary when a part is not produced within the correct tolerance or has poor surface finish or other defects.

scanners

A device that captures visual data. Scanners read universal product codes in an electronic kanban system.

service

Any non-physical work that a company provides for a customer. Services include storing products and providing customer service.

service workflow

The steps information takes as it moves between an organization and the customer during the creation of a product or service. Service workflow includes tasks such as receiving customer orders, providing customer service, and troubleshooting.

single-piece flow

A production method that creates one part at a time. Single-piece flow helps ensure consistent flow and reduces waste since errors can be identified before they can affect an entire batch.

software

The instructions, formulas, and operations that structure the actions of a computer. Software often consists of a computer program or application.

solder

A process in which a filler metal is melted at low temperatures to form a joint between two base metals. Soldering is often used for delicate projects such as jewelry and electronics.

spaghetti diagrams

A visual tool that represents the layout of a workspace and uses lines to indicate the movement of materials and people through it. Spaghetti diagrams are helpful for identifying areas of wasted movement.

stamping press

A machine with a stationary base and an upper slide that repeatedly moves up and down. A stamping press shapes or cuts metal to create useful parts for a range of industries.

standardized

Following established universal processes that produce repeatable, predictable outcomes each time the work is done. Standardized practices help to eliminate waste from processes.

steel

A metal consisting of iron and carbon, usually with small amounts of other elements. Steel is the most common manufacturing metal.

suppliers

An organization that provides materials or parts to manufacturing companies. Suppliers can become connected with consumers as a result of manufacturing processes and organizations.

supply chain

A network of companies that exchange resources such as materials and information to deliver products to customers. Supply chains consist of a company, its suppliers, its distributors, and its customers.

takt time

The rate at which a customer requires a company to manufacture products. Takt time is equal to the amount of available work time, usually expressed in minutes, divided by the number of product orders per day.

tangible

Physical in nature. Tangible barriers to flow include equipment breakdowns, supply chain disruptions, and limited physical space.

transmission

A machine that uses a combination of gears and other mechanical components to change the speed or torque of mechanical energy. Some transmissions can also change the direction of mechanical energy.

universal product code

UPC. A combination of a number and a series of parallel lines, known as a barcode, that communicates digital information. Universal product codes can be scanned to automatically enter information about inventory and part movement into a computer system.

unnecessary motion

Increased movement that occurs while completing a task, such as searching for tools or parts due to a poorly structured work environment. Unnecessary motion wastes time that could be spent doing valuable work.

unnecessary transportation

Any effort made to move an object from one location to another that is not required. Unnecessary transportation may lead to product damage.

upstream activities

Any task that occurs before other downstream tasks in a process. Upstream activities often include purchasing raw materials and initial processing.

value

The real or perceived worth of a product or service to the customer. Value includes the qualities of a product, such as its functionality, reliability, and availability.

value added

Any activity that increases the worth of a product for the customer. Value-added activities are those that a customer is willing to pay for, such as machining, grinding, and finishing.

value stream

The series of activities involved in creating a product. A value stream involves the involving the flow of materials and information, a customer, and a supplier.

value stream map

A sophisticated flow chart that uses symbols, metrics, and arrows to help visualize processes and track performance. Value stream maps help determine which steps of a process add value and which do not.

value stream mapping

VSM. The process of creating a visual layout of all the processes required to make and deliver a product. Value stream mapping helps determine which parts of a process can be adjusted to improve flow.

variation

Any deviation from what is normal and consistent. In manufacturing, variation from what is normal can signal that an error has occurred.

VSM

Value stream mapping. The process of creating a visual layout of all the processes required to make and deliver a product. VSM helps determine which parts of a process can be adjusted to improve flow.

waiting

Any time spent while products or employees remain idle. Waiting does not add value for the customer.

waste

Any element of the manufacturing process that does not add value to a product or process. The goal of lean manufacturing is to eliminate waste.

welded

To join two pieces of metal together permanently at a point of contact. Welded materials are joined by applying heat, pressure, or both heat and pressure.

WIP

Work-in-process. A part that has undergone some but not all necessary manufacturing processes. A WIP product has been converted from raw materials but is not yet a finished good.

withdrawal kanban

A signal that the work area consuming parts needs more parts brought from inventory to the production area. Downstream processes will send a withdrawal kanban to upstream processes when they need more materials.

workcells

A specialized grouping of people, machines, and materials involved in the creation of a specific product or involved in a single task. Workcells are designed to complete a process’s steps in a sequential order.

work-in-process

WIP. A part that has undergone some but not all necessary manufacturing processes. A work-in-process product has been converted from raw materials but is not yet a finished good.

work-in-process flow

The movement of products within an organization that have undergone some manufacturing processes but are not yet finished. Work-in-process flow includes activities such as molding, grinding, and forming.