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Buzz Word Tech Share

September 21, 2009



Kaizen

• Kaizen refers to a philosophy focusing oncontinuous improvement in manufacturingactivities, all business activities, or even allaspects of life.

• When used in the business sense and applied tothe workplace, Kaizen typically refers to activitiesthat continually improve all functions of abusiness, from manufacturing to management

and from the CEO to the assembly line workers.

By improving standardized activities andprocesses, Kaizen aims to eliminate waste .



Six Sigma

• Six Sigma seeks to improve the quality of processoutputs by identifying and removing the causes of defects (errors) and Variability in manufacturing andbusiness processes. It uses a set of quality

management methods, including statistical methods,and creates a special infrastructure of people withinthe organization ("Black Belts","Green Belts", etc.) whoare experts in these methods. Each Six Sigma project

carried out within an organization follows a definedsequence of steps and has quantified financial targets(cost reduction or profit increase).



Lean

• Lean manufacturing or " Lean", is a production practice thatconsiders the expenditure of resources for any goal other than thecreation of value for the end customer to be wasteful, and thus atarget for elimination. Working from the perspective of thecustomer who consumes a product or service, "value" is defined as

any action or process that a customer would be willing to pay for.• Basically, lean is centered around creating more value with less

work .

• Lean manufacturing is a variation on the theme of efficiency basedon optimizing flow; it is a present-day instance of the recurringtheme in human history toward increasing efficiency, decreasing

waste, and using empirical methods to decide what matters, ratherthan uncritically accepting pre-existing ideas.



Value Stream Mapping

• Value stream mapping is a Lean technique

used to analyze the flow of materials and

information currently required to bring a

product or service to a consumer.



Kanban

• Kanban (where kan means “visual,” and ban means"card" or "board") is a concept related to lean and just-in-time (JIT) production. The Japanese word kanban isa common term meaning “signboard” or “billboard.”

• Kanban is a signaling system to trigger action. Kanbanhistorically uses cards to signal the need for an item.However, other devices such as plastic markers or ballsor an empty part-transport trolley or floor location can

also be used to trigger the movement, production, orsupply of a unit in a factory.



Examples of Kanban Boards



Just-In-Time (JIT)

• Just-in-time (JIT) is an inventory strategy thatstrives to improve a return on investment byreducing in-process inventory and associated

carrying costs.• To meet JIT objectives, the process relies on

signals or kanbans between different points inthe process, which tell production when to make

the next part. Implemented correctly, JIT candramatically improve a manufacturingorganization‘s ROI, quality, and efficiency.



5S

• 5S is the name of a workplace organization methodologythat uses a list of five Japanese words which, translated intoEnglish, start with the letter S. 5S is a philosophy and a wayof organizing and managing the workspace and work flowwith the intent to improve efficiency by eliminating waste,

improving flow and reducing process unevenness.• The 5S's are:

• Phase 1 - Sorting

• Phase 2 - Straighten or Set in Order

• Phase 3 - Sweeping or Shining• Phase 4 - Standardizing

• Phase 5 - Sustaining the discipline



6S

• A sixth phase, "Safety," is sometimes added.

Purists, however, argue that adding it is

unnecessary since following 5S correctly will

result in a safe work environment. Often,

however a poorly conceived and designed 5S

process can result in increases in workplace

hazard when employees attempt to maintaincleanliness at the expense of ensuring that

safety standards are adequately followed.



Poka-Yoke

• Poka-yoke is a Japanese term that means "mistake-

proofing". A poka-yoke is any mechanism in a lean

manufacturing process that helps an equipment

operator avoid mistakes. Its purpose is to eliminateproduct defects by preventing, correcting, or drawing

attention to human errors as they occur.

• More broadly, the term can refer to any behavior

shaping constraint designed into a product to

prevent incorrect operation by the user.



Poka-Yoke Examples

• Examples of poka-yoke in consumer products include:

• Automatic Transmissions: the inability to remove a car key from the ignition switch of an

automobile if the automatic transmission is not first put in the "Park" position, so that the

driver cannot leave the car in an unsafe parking condition where the wheels are not locked

against movement.

• 3.5” Floppy Disks: the top-right corner is shaped in a certain way so that the disk cannot be

inserted upside-down.

• High-security padlocks: it is impossible to remove the key from some high-security padlocks

unless the shackle on the padlock is closed. Only by locking the padlock can the key be

removed.

• UK 13 Amp Electric Plugs: it is impossible to wrongly insert the plug into the socket, due to its

arrangement of three rectangular pins.

• Microwave Ovens: a door switch automatically disconnects the activation button when the

door of the oven is opened. As a result, it is impossible to cook anything in a microwave oven

unless the door is fully closed.

• SIM (Subscriber Identity Module) Cards: The SIM card used in cellular phones has its upper

left corner trimmed diagonally to guide the card correctly into position.



SMED

• Single Minute Exchange of Die ( SMED) is one of themany lean methods for reducing waste in amanufacturing process. It provides a rapid and efficientway of converting a manufacturing process from

running the current product to running the nextproduct. This rapid changeover is key to reducingproduction lot sizes and thereby improving flow. Thephrase "single minute" does not mean that allchangeovers and startups should take only one minute,

but that they should take less than 10 minutes. Closelyassociated is a yet more difficult concept, One-TouchExchange of Die, (OTED), which says changeovers canand should take less than 100 seconds.



Acronyms

• OFI – Opportunity for Improvement

• ISO – International Organization for Standardization

• LEPC – Local Emergency Planning Committee

•

TRI – Toxic Release Inventory• IMDS – International Material Data System

• MSDS – Material Safety Data Sheet

• CAR – Corrective Action Report

• PAR – Preventive Action Report

• SW3P or SWPPP – Storm Water Pollution Prevention Plan

• BMP – Best Management Practice



And in case you are behind…

• lol – laugh out loud

• tyvm – thank you very much

•

ttyl – talk to you later• idk – I don’t know

• nm – nevermind

• OMG – Oh My Gosh!

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