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A mechanism in lean manufacturing that helps an equipment operator avoid mistakes. Its aim is to eliminate product defects by preventing, correcting, or drawing attention to human errors. Use it to reduce the possibility of defects.

An acronym for Define, Measure, Analyze, Design, and Verify. It's a data-driven quality strategy used to design products and processes. Use when creating new product or process designs.

A tool that summarizes the inputs and outputs of one or more processes in table form. SIPOC stands for Suppliers, Inputs, Process, Outputs, and Customers. Use it at the beginning of a project to give all team members a high-level overview.

A statistical tool used to monitor a process and determine whether it's in a state of control. It helps in detecting trends or abnormalities. Use to monitor ongoing processes.

A measure of the amount of variation or dispersion of a set of values. In the context of Six Sigma, it's typically used to analyze process variability. Use it to determine the predictability of your processes.

A lean-management tool for analyzing the current state and designing a future state for the series of events that take a product or service from the beginning through to the customer. Use it to identify and eliminate waste.

A production strategy that strives to improve a business return on investment by reducing in-process inventory and associated carrying costs. Use it to minimize waste and increase efficiency.

An acronym for Define, Measure, Analyze, Improve, and Control. It's a data-driven improvement cycle used for improving, optimizing and stabilizing business processes and designs. Use when aiming to improve an existing business process.

A method of problem-solving that tries to identify the root causes of faults or problems. It's a collective term that uses various tools like Fishbone Diagram, 5 Whys, etc. Use it to solve complex problems by addressing the true cause.

Also known as an Ishikawa diagram, it's a cause-and-effect diagram that identifies potential causes for an effect or problem. Use it to brainstorm potential root causes of a defect or problem.

A philosophy that focuses on continuous improvement across all functions of an organization. It involves employees at every level. Use it for process improvement in small incremental steps.

A graphical representation of the distribution of numerical data. It helps to estimate the probability distribution of a continuous variable. Use it to visualize the spread of process data and look for signs of process behavior.

A process of comparing one's business processes and performance metrics to industry bests or best practices from other industries. Use it to identify areas, systems or processes for improvements.

A statistical method used to test differences between two or more means. It can help determine if any of the differences between the means are statistically significant. Use it when comparing three or more groups for statistical difference.

A term that describes the in-depth process of capturing customer's expectations, preferences and aversions. Use it to ensure that customer needs and wants are reflected in process improvement efforts.

A management practice for leaders to walk the shop floor in manufacturing, or where work happens, with the goal of identifying wasteful activities and understanding the real work process. Use it for active observation and engagement.

A problem-solving method that involves asking 'Why?' five times to drill down into the root cause of a problem. Use it when problems involve human factors or interactions.

A step-by-step approach for identifying all possible failures in a design, a manufacturing or assembly process, or a product or service. Use it to anticipate possible failures and mitigate risk.

A separate and emerging discipline related to Six Sigma, focused on the design or redesign of the different processes used in product manufacturing or service delivery, aiming for no defects. Use it when designing new products or processes.

A theory for product development and customer satisfaction developed by Noriaki Kano. It categorizes customer preferences into delighters, satisfiers, and dissatisfiers. Use it to analyze and prioritize customer needs and expectations.

A bar graph that represents the frequency or impact of problems. It's used to prioritize issues based on their cumulative impact. Use it to identify and focus on issues that will have the greatest overall effect if solved.

A method in which product or information moves quickly through a process with minimal (or no) buffers between steps of the manufacturing process. Use it to reduce cycle times and inventory levels in production.

A tool that translates customer needs or wants into measurable requirements. CTQ stands for Critical to Quality. Use it to clearly understand and define what criteria the process or product must meet to satisfy customer expectations.

A visual feedback system for the shop floor that indicates production status, alerts when assistance is needed, or signals that a part is defective. Use it to support quick response to issues and promote resolution.

A holistic approach to equipment maintenance that strives to achieve perfect production. It emphasizes proactive and preventative maintenance to maximize the operational efficiency of equipment. Use it for reducing machine downtime.

A process that dramatically reduces the time it takes to complete equipment changeovers. The acronym SMED stands for Single-Minute Exchange of Dies. Use it to reduce setup times and improve process flexibility.

A visual representation of the steps in a process. Use to understand and analyze the current process (as-is) and design the future process (to-be).