Lean Manufacturing Overview 101

andon

A visual management tool that highlights the status of operations in an area and that signals whenever an abnormality occurs. Andon lights can be used as error-proofing devices.

batch

A specific number of the same part that moves through the production cycle. Small batch manufacturers produce a variety of different products but in low volume.

breakdown

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

continuous improvement

The belief that an organization must constantly measure the effectiveness of its processes and strive to meet more difficult objectives to satisfy customers. Continuous improvement is a guiding principle in lean manufacturing.

cutting tools

A device with one or more edges that is designed to cut metal. Cutting tools are often designed to be used on a machine tool, such as a mill or lathe.

cycle time

The actual time it takes to perform a task and forward it to the next step. One major goal of lean manufacturing is to match cycle time to the rate of customer demand.

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.

electronic kanban

ekanban. A digital method used to signal production and material movement. Common electronic kanban methods include email or scanned barcodes.

error detection

The inspection of a part before it has been completed to determine if it conforms to specifications. Error detection discovers errors after they have occurred.

error-proofing devices

Any tool or process used to reduce or eliminate errors from a manufacturing process. Error-proofing devices might use andon lights or other means to signal that a problem has occurred.

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.

Five S

5S. A targeted list of activities that promotes organization and efficiency within a workspace. The Five S terms are sort, set in order, sweep, standardize, and sustain.

fixtures

A customized workholding device used to position and hold a workpiece during a manufacturing process. Fixtures are often built to hold a specific part design.

in-process

To have undergone some but not all necessary manufacturing processes. An in-process product has been converted from raw materials but is not yet a finished good.

inspection

The examination of a part to determine if it conforms to specifications. Inspection traditionally follows the completion of a part.

inventory

The storage of raw material, in-process parts, and completed, manufactured products. In lean manufacturing, excess inventory is considered waste.

kanban

A Japanese word meaning 'card signal.' Kanban represents any visual method used to show the need for parts or products to be moved or produced in a lean system.

lead times

The time spent between the original customer order for a particular product and its final delivery to the customer. Manufacturers try to reduce lead time to improve customer satisfaction.

lean manufacturing

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

material handling

The strategy and devices used to move and store materials during the production cycle. Transferring materials, packaging, and palletizing are examples of material handling.

multiple batch production

A manufacturing method that produces a group of products in a single time period rather than one at a time. Multiple batch production leads to wasted time.

overprocessing

Putting effort into unnecessary tasks or failing to use the most efficient production methods. Overprocessing wastes resources and does not add value to the product.

overproduction

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

processes

A series of activities required to complete a product or provide a service to a customer. Processes can include material handling, machining, inspecting, and other activities.

product changeovers

The time it takes to tear down the setup for the current product type, prepare for next product type, and successfully produce the first good part. Manufacturers use different strategies to reduce product changeover time.

product flow

The movement of products within the facility during each stage of the products' manufacturing process. Lean manufacturing seeks to streamline product flow.

pull system

A production system in which components are not delivered to machines until they are needed. Pull systems are characterized by smaller batches, quick responses to customer demand, and smooth product flow.

quality

The satisfaction of 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.

raw material

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

safety

The step in 6S and 7S that identifies, documents, and removes potential safety hazards from a workspace. Safety is the sixth step in the 6S and 7S approach.

scrap

Any part or byproduct material not sold as a product. Scrap includes unused material that naturally results from a process, such as chips from machining operations, as well as parts that are unsellable or destroyed due to defects.

set in order

The step in 5S that involves organizing the workplace to ensure easy access and optimal efficiency. Set in order, also known as straightening, is the second step in the 5S approach.

Seven S

7S. A modification of 5S that includes two additional steps, safety and spirit. Seven S focuses on creating safer working conditions that protect against potential hazards, as well as maintaining a cooperative environment.

single minute exchange of dies

SMED. A theory of setup reduction that strives to reduce the time it takes to perform product changeover. The single minute exchange of dies approach strives to reduce changeover time to under ten minutes.

Six S

6S. A modification of 5S that includes a sixth step, safety. Six S, or 5S+1, focuses on creating safer working conditions that protect against potential hazards.

sort

The step in 5S that involves separating unnecessary materials from required materials in the workplace to eliminate clutter and create additional space. Sort is the first step in the 5S approach.

spirit

The step in 7S that engages employees at all levels to promote cooperation and teamwork. Spirit is the seventh step in the 7S approach.

standardize

The step in 5S that involves documenting and implementing methods to maintain a clean, safe, and organized workspace. Standardize is the fourth step in the 5S approach.

sustain

The step in 5S that involves implementing programs and procedures to ensure the Five S steps continue to occur over time. Sustain is the fifth step in the 5S approach.

sweep

The step in 5S that involves cleaning and inspecting all areas of the work environment. Sweep is the third step in the 5S approach.

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 transport

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

value

A real or perceived quality that satisfies the needs and wants of a customer. Value includes the features of a product as well as other qualities associated with the product.

variation

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

waiting

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

waste

Any inefficiency or unnecessary activity within the manufacturing process that does not add value to the product or process. Waste includes excess inventory, defects, overproduction, unnecessary motion, and waiting times.

work cells

An arrangement of machines, tooling, materials, and operators structured around the design of similar products. Work cells encourage smooth product flows and use space efficiently.