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A workplace organization method that uses a list of five Japanese words: seiri, seiton, seiso, seiketsu, and shitsuke. These translate to sort, set in order, shine, standardize, and sustain. The 5S methodology helps to create a clean, orderly, and safe work environment and improve efficiency.

A scheduling system for lean manufacturing and just-in-time manufacturing. Kanban is a visual system for managing work as it moves through a process, signaling when to move or produce more inventory.

An inventory management strategy that aligns raw-material orders from suppliers directly with production schedules. It is used to increase efficiency and decrease waste by receiving goods only as they are needed.

A lean-management method for analyzing the current state and designing a future state for the series of events that take a product or service from its beginning through to the customer.

A concept referring to business activities that continuously improve all functions and involve all employees from the CEO to the assembly line workers. Kaizen sees improvement in productivity as a gradual and methodical process.

A Japanese term that means 'mistake-proofing' or 'inadvertent error prevention.' A poka-yoke is any mechanism in a lean manufacturing process that helps an equipment operator avoid mistakes. Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur.

A visual control device showing machine, process, or line status, often found in manufacturing environments. An andon system can indicate line slowdowns, stoppages, or quality issues and alert management or maintenance personnel.

A series of techniques designed to reduce the time it takes to complete equipment changeovers. The name reflects the goal of being able to change out a machine or process within a single digit minute time frame.

A holistic approach to equipment maintenance that strives to achieve perfect production. TPM emphasizes proactive and preventive maintenance to maximize the operational efficiency of equipment.

A Japanese term for production smoothing or leveling. The goal of heijunka is to produce goods at a constant rate so that further processes may also be carried out at a constant and predictable rate.

Refers to automation with a human touch, i.e., machines are stopped immediately when a problem is detected. This allows for immediate intervention to resolve the issue, preventing defects from continuing down the line.

A Japanese term meaning 'the real place.' In business, it refers to the place where the real work is done, where the value is added, often used to emphasize the importance of going to the factory floor to understand the current state.

The rate at which a complete product or service must be finished in order to meet customer demand. It's calculated by dividing the available production time by the rate of customer demand using the equation

Detailed definition of the most efficient method to produce a product (or perform a service) at a balanced flow to achieve a desired output rate. It breaks down the work into elements, which are sequenced, organized, and repeatedly followed.

The A3 problem-solving method is a structured approach to problem-solving and continuous improvement. The A3 report, which is typically a large piece of paper, reflects the problem, analysis, corrective actions, and action plan on a single sheet. It encourages root cause analysis, a clear problem statement, and a structured approach.

A principle of lean manufacturing that involves the smooth progression of materials and work through the production process with minimal buffers between steps. The goal is to move products through production with as little waste as possible.

An inventory control system that authorizes production based on actual customer demand. In contrast to a push system, pull systems strive to reduce overproduction and excess inventory by producing only what is needed, when it is needed.

These are three Japanese terms used to describe three different types of waste in a lean manufacturing system. Muda refers to the non-value-adding activities, Mura to the unevenness in production, and Muri to overburdening equipment or employees.

A strategic planning method used to ensure that the strategic goals of a company drive progress and action at every level within that company. This eliminates the waste that comes from inconsistent direction and poor communication.