Japnese Term

Muda
Mura
Muri
Kiazen
Hansei
Jidoka
Heijunka
Genchi Genbutsu
Lean Practices
Creating Flow
Takt Time

Heijunka
SMED
5S
Automation
Jidoka
Poka Yoke
Visual Controls
Genchi Genbutsu
5 Why
Standardization

Meaning
Waste
Uneveness Worload
Over burden
Continuous Improvement
Self Reflection, meaning to acknowledge one's own mistake and to pledge improvement
Stop when there is a problem (Intelligent Automation)
Level out the Workload
Go See yourself
Lean Practices
Redcues WIP & Finished Goods Inventory/ Drives Efficiency in operations| Surfacing Problems Ea
German word (Taktzeit), rhythmic time, to operate at a steady state.
'= Available Time/ Customer Demand
Benefits - Production Stability, Efficient Workcell design, Communication of production rate
Work planning tool to meet Customer demand & can help to derive team size too | Production Pla
Level out the Workload
Benefits : flexibitly to make what customers want & when they want, reduce risk of unsold goods, b
demand on upstream process & suppliers
esnures workload levelling by reducing lot size and stock levels
Displace, Eliminate, Reduce, Standardize, Autmate

Sort (wanted/ unwanted items) Straighten (organize items, identify location, place them close) S
rules for 1st 3 steps, display rules, training for identifying defects) Sustain (Maintain orderliness, L
Institutionalize the process)

Save time/ effort. Consistent Quality/ Quantity

Stop when there is a problem (Intelligent Automation), drives Quality, Do it first time right.
Improved Quality, Problem identification, at problem occurrence with less human monitoring effort
Mistake Proofing. Golden Rules : Dont accept a mistake, Dont make a defect, Dont pass on a defe
Checklist based on past defects, Automated tests, guiding philossophy is defect prevention
Signs, Information Display, Layouts
Go See yourself/ first hand info/ direct observation/ know work environement, interact with Team
Actual Causes of failures
Standard Input, Process & Output

4 Principles
Philosophy

Process
(Eliminate Wastes)

People & Partners

Problem Solving

Production Planning
Process Improvement
Work Station
Efficiency
Process Improvement
Process Efficiency
Surfacing Problems Early
Surfacing Problems Early
Surfacing Problems Early
Problem Solving
Process Improvement
Process Improvement

4 Principles
Long term objectives foe the Organization
Automation
Jidoka (Stop when there is a problem)
SMED (Fast Changeover)
Heijunka (Level out the Workload)
Standardization
Visual Controls
Create Process Flow
Use Pull system (to avoid overprodcution)
Grow leaders who live the philosophy & provide opportunity to team & people
Respect, develop, challenge your Team, help suppliers attain high performance
Genchi Genbutsu (Go See yourself)
Kiazen (Continuous Improvement)
Hansei (Self reflection)