http://www.scribd.com/doc/5396036/The-Illustrated-Lean-Agile-and- orld-!lass-"anu#acturing!oo$boo$-%00&-0&-%0'is'a'great'site(((( Abandon'#i)ed'ideas Thin$'o#'wa*s'to'ma$e'it'possible +o'e)cuses'needed ,o'#or'the'simple'solution-'not'the'per#ect'one !orrect'mista$es'now .se'*our'ideas-'do'not'hide'them'.se'*our'wits-'not'*our'wallet /roblems'are'opportunities 5' h*s'wh*'did'the'de#ect'occur-'wh*'that00.

1ee$'ideas'#rom'man*'people There'is'no'end'to'impro2ement 1eparate'human'3'machine'wor$'4do'not'mi)'the'#low'times'together'or'5ualit*6 7limination'o#'"uda'4waste'or'non-2alue'added6 !ardinal'sin'is'waste:'waste'o#'material'4scrap-'not'used'4cut'o##6-'8,'not'sold'at'determined' price6-'waste'o#'time-'transportation-'processing-'in2entor*-'motion-'5ualit*'issues-'wasted' resources-' 3!'!oncern-'!ontainment'!ountermeasure' 3d'9irt*-'dangerous'di##icult' 5'wh*s'and'!/: ;oshin'/lanning

4"etlen<s'comments'in'green='red'are'>ust'words'that'leapt'at'"etlen'6The'Hoshin Planning Process is'a' s*stematic'planning'methodolog*'#or:'?6'de#ining'the'long-range'$e*'ob>ecti2es'o#'the'organi@ation'or' compan*='and'%6'ensuring'the'implementation'o#'Abusiness'#undamentals'A'these'would'be'business'rules-' all'processes-'and'metrics're5uired'to'success#ull*'run'the'business'on'a'dail*'basis.'';oshin'planning-' there#ore-'is'a'two-prong'planning'approach'that'co2ers'the'organi@ationAs'strateg*'to'achie2e' brea$through'results'through'its'long-term'ob>ecti2es'and'ensure'continual'impro2ement'through'its' short-term'business'#undamentals.' ''''''''''''' Li$e'man*'modern'business'concepts'toda*-'hoshin'planning'was'de2eloped'in'Bapan'the'name'and' disciplined'approach-'not'the'concept.'The'concept'has'been'around'#ore2er'in'organi@ations'that'are' success#ul'in'a'competiti2e'en2ironment..'The'Bapanese'words'Ahoshin'$anriA'can'be'translated'into' Adirection'settingA.''And'li$e'man*'Bapanese'management'concepts-'hoshin'planning'also'promotes'the' in2ol2ement'o#'all'emplo*ees'in'the'process-'on'the'basic'premise'that'desired'results'can'onl*'be' attained'i#'e2er*bod*'in'the'organi@ation'#ull*'understands'the'goals'o#'the'compan*'and'is'somehow' in2ol2ed'in'the'AchainA'o#'plans'de#ined'to'achie2e'them'recogni@e'TC"<s'Dgoal'congruenc*<. ''' '' The'plan'generated'b*'the';oshin'process'is'hierarchical'in'nature-'with'the'corporate'ob>ecti2es' determining'the'corporate'strategies'which-'in'turn-'are'supported'b*'lower-le2el'strategies'that'cascade' down'the'organi@ation'loo$s'a'lot'li$e'the'three'la*ers'and'goal'congruenc*'to'me.''In'e##ect-'the'goals'o#' e2er*'indi2idual'should'support'the'goals'o#'the'ne)t'person'up'in'the'hierarch*.'72er*'strateg*'#urther' consists'o#'tactics'or'actions'that'need'to'be'underta$en'to'accomplish'the'strateg*.'This'is'where'the'#i2e' 5uestions'come'in:'relati2e'to'*our'goals-'?6'where'are'*ou-'%6'wh*'are'*ou'there-'36'where'do'*ou'want' to'go-'E6'how'are'*ou'going'to'get'there-'and'56'is'it'worth'it '''' The'hoshin'planning'process'basicall*'consists'o#'the'#ollowing'steps:'?6'identi#ication'o#'critical'business' issues'that'the'organi@ation'#aces'FT'o#'1 FT='%6'establishment'o#'business'ob>ecti2es'to'address'these' issues='36'de#inition'o#'the'compan*As'o2er-all'goals='E6'de2elopment'o#'strategies'that'support'the'o2er-all' goals='56'de#inition'o#'sub-goals'or'tactics'that'support'each'strateg*='66'establishment'o#'metrics'or' indicators'#or'measuring'process'per#ormance='and'G6'establishment'o#'business'#undamental'measures.'' The'#irst'3'steps'o#'this'process'are'handled'b*'top'management-'with'the'de#ined'o2er-all'goals' supported'b*'the'rest'o#'the'organi@ation'through'steps'E-G.'It'would'be'great'to'wea2e'these'points'into' *our'conceptual'statement-'let'me'rephrase'that-'wea2e'these'points'into'*our'conceptual'statement '''''''''''''''''''' An'important'aspect'o#'the';oshin'process'is'the'regular're2iew'o#'the'de#ined'plans.'It'is'not'enough'to' ha2e'a'documented'plan'-'it'needs'to'be'chec$ed'against'actual'per#ormance.'';oshin'plans'must' undergo'a'ma>or're2iew'at'least'once'a'*ear'continuous'would'be'the'most'competiti2e-'that'is'what' control'charts'lin$ed'to'automatic'measuring'are'#or.'9uring're2iew-';oshin'plans'are'usuall*'presented' using';oshin're2iew'tables-'each'o#'which'shows'a'single'ob>ecti2e'and'its'supporting'strategies.'A'group' or'indi2idual'responsible'#or'se2eral'ob>ecti2es'there#ore'needs'to'generate'se2eral're2iew'tables'in'order' to'co2er'all'ob>ecti2es.'.nderstand'and'measure'the'causal'2ariables'and'ha2e'control'charts'#or'each' o2erlaid'with'the'chart'trac$ing'the'output'metric-'thus'there'is'continuous're2iew' '''''''''''''''' The'#ollowing'details'must'be'shown'#or'each'strateg*'in'the're2iew'table:'?6'the'strateg*'owner4s6='%6'the' time#rame='36'the'per#ormance'metrics='E6'the'target4s6'on'control'charts'as'target'#or'each'strateg*'as' de#ined'during'the';oshin'planning'process='and'56'the'actual'results'at'the'time'o#'the're2iew.''An*' discrepanc*'between'the'target'and'actual'results-'whether'positi2e'or'negati2e-'must'be'noted'along' with'the'impact'o#'the'discrepanc*'on'ne)t'*earAs'plans.'As'mentioned'earlier-'hoshin'plans'are' hierarchical'in'nature-'cascading'#rom'the'top'le2els'to'the'lower'ones-'so're2iew'tables'must'li$ewise' cascade'upwards. '''' He#lection-'>ust'li$e'in'the'last'step'in'/ro>ect'"anagement'which'is'the'anal*sis'o#'what'went'right'or' what'went'wrong'in'each'strateg*'and'what'should/could'ha2e'been'done'to'impro2e'all-'is'an'important' aspect'o#'hoshin're2iews.'9etermining'ob>ecti2el*'what'were'done'right'in'strategies'that'attained'the' desired'results'and'what'need'to'be'impro2ed'in'strategies'that'#ailed'to'hit'their'targets'is're5uired'in'the' organi@ationAs'learning'process'onl*'good'i#'becomes'embedded'in'processes'and/or'data'base.'Tacit'

$nowledge'has'to'be'institutionali@ed'in'some'manner.'Anal*ses'o#'how'the'strategies'#ared'must'be' done'in'terms'o#'detailed'supporting'data'see'control'chart'idea'abo2e. '''''''''''' There'is'actuall*'another'set'o#'tables'used'in';oshin'planning-'i.e.-'the'strateg*'implementation'planning' tables.'Implementation'plans'are'used'to'identi#*'the'tactics'or'action'plans'needed'to'accomplish'each' strateg*.'Implementation'plans'usuall*'present'the'#ollowing'in#ormation:'?6'the'tactics'needed'to' implement'the'strateg*='%6'the'people'in2ol2ed'in'each'tactic'and'their'e)act'responsibilities='36'the' timeline'o#'each'tactic-'usuall*'presented'as'a',antt'chart='E6'per#ormance'measures='and'56'how'and' when'the'implementation'plans'will'be're2iewed.'/oints'to'wea2e'into'*our'#inal'report(( ''' Ie*'strategies'cannot'be'pursued'e##ecti2el*'unless'the'compan*As'operations'are'sound'and'stable.'This' is'the'reason'wh*'the';oshin'planning'process'also'in2ol2e'the'de#inition'o#'business'#undamentals'and' their'metrics-'which'are'documented'in'a'business'#undamental'table.'':usiness'#undamentals-'or'the' basic'elements'that'de#ine'the'success'o#'a'$e*'business'process'clari#ication'here-'in'the'#irst'paragraph' the'authors'are'tal$ing'li$e'the'processes'are'#undamentals-'here'the*'are'sa*ing'that'the'#undamentals' are'what'measure'the'processes.'Let'us'sa*'that'business'rules-'all'processes-'and'metrics'are' #undamentals'and'all'are'monitored'through'metrics'4*es'e2en'metrics'can'be'measured6'-'are'monitored' through'its'corresponding'metrics.''These'business'#undamental'metrics'indicate'whether'or'not'the' 2arious'2alue-adding'operations'or'acti2ities'are'doing'well'In'a'strict'sense-'most'processes'are'not' 2alue'adding-'the'onl*'2alue'added'steps'are'direct'trans#ormation'o#'stu##'into'more'2aluable'stu##'that'is' sold.''Thus-'the'onl*'steps'that'should'be'retained'in'an'organi@ation'are'those'in'production.'Fb2iousl*' this'is'not'possible-'so'the'de#inition'o#'what'is'2alue'added'needs'to'be'e)panded.' h*'wouldn<t'the*'be' measuring'non'2alue'added'steps-'the*'also'should'be'controlled'i#'the*'are'not'eliminated.':8T'#igures' must'be'in'control'be#ore'the'long-term'strategies'are'attended'to. ''' Lastl*-';oshin'planning-'to'be'trul*'e##ecti2e-'must'be'cross-#unctional-'i.e.-'the*'must'promote'intra-'and' inter-process'cooperation.''This'onl*'re#lects'the'realit*'that'the'2arious'departments'o#'a'compan*'need' to'support'each'other'in'order'to'achie2e'remar$able's*nergistic'results.'7nterprise'wide'processes'and' the'three'wa*s'o#'integration'4#low-'share-'#it6 '''''''''''''''''''''''''''''''''''''''''''''' /rimar*'He#erence:''www.5ualit*digest.com

;ei>un$a:'le2el'production

Heijunka: Leveling the Load

1eptember'?-'%00E The slower but consistent tortoise causes less waste and is much more desirable than the speedy hare that races ahead and then stops occasionally to doze. The Toyota Production System can be realized only when all the workers become tortoises. Why not the hare that races in the correct direction and does not need to stop, the hare would always win. - Ohno, 1 !! "an*'companies'toda*'are'wor$ing'towards'the'ultimate'Lean'goal'o#'continuous'or'one-piece'#low.'The*' want'to'be'able'to'ma$e'>ust'what'the'customer'wants'when'the*'want'it'unless'demand'is'stead*-'means' mar$eting'has'to'control'orders-'then'to'do'one-piece'#low'when'the'customer'wants'it-'a'#irm'would'ha2e' to'hurr*'and'then'not'hurr*.''Instead-'what'we'o#ten'see'is'a'Jhurr*'up-'then'slow'downK'build-to-order' approach.'!ustomers<'orders'2ar*'#rom'month'to'month-'creating'une2en'production'scheduling.'':uild-toorder'companies'will'be'building'huge'5uantities-'pa*ing'o2ertime-'and'stressing'their'people'and' e5uipment'one'wee$-'but'then'sending'them'home'the'ne)t'due'to'light'orders.'This'en2ironment'can'also' create'large'amounts'o#'in2entor*-'hidden'problems-'and'poorer'5ualit*.' hat'man*'organi@ations'#ail'to'

do'is'the'di##icult'process'o#'creating'a'true'balanced'lean'wor$#low.''This'is'the'To*ota'concept'o#' hei"unka, le2eling'out'the'wor$'schedule. #ei"unka is'the'le2eling'o#'production'b*'both'2olume'and'product'mi).'This's*stem'does'not'build' products'according'to'the'actual'#low'o#'customer'orders.'#ei"unka ta$es'the'total'2olume'o#'orders'in'a' period'and'le2els'them'out'so'the'same'amount'and'mi)'are'being'made'each'da*'sounds'li$e' #orecasting'and'push'to'me-'or'putting'the'uncertaint*'o'#'the'#uture'on'the'shoulders'o#'the'customer'.'In' a'true'build-to-order's*stem'*ou'build'products'A and'B'in'the'production'se5uence'o#'customer'orders' 4e.g.-'A, A, B, A, B, B, B, A'06.'This'causes'*ou'to'build'product'irregularl*.'I#'*our'orders'are'twice'as' much'on'"onda*'compared'to'Tuesda*-'*ou'end'up'pa*ing'o2ertime'on'"onda*'and'sending'emplo*ees' home'on'Tuesda*.''The'answer'is'to'build'a'le2el'schedule'e2er*da*'b*'ta$ing'the'actual'customer' demand'*ou'are'assuming'*ou'$now'this'#ar'enough'in'ad2ance'that'*ou'can'do'this-'a'lu)ur*'most'do'not' ha2e-'determine'the'pattern'o#'2olume'and'mi)-'and'building'*our'le2el'schedule'That'is'#ine'i#'*ou'ha2e' le2el'and'consistent'demand.'I#'*ou'$now'*ou'are'ma$ing'#i2e'A<s'and'#i2e':<s-'*ou'create'a'le2el' schedule'o#'ABABABAB why not AAAAABBBBB unless you are delivering after every AB .'This'is' called'le2eled-'mi)ed-model'production. Figure 1'gi2es'an'e)ample'o#'traditional'unle2eled'production-'#or'!ompan*'L'that'manu#actures'tractors.' The'line'ma$es'small-'medium-'and'large'tractors.'The'medium'are'the'big'sellers'and'are'made'earl*'in' the'wee$-'"onda*'through'part'o#' ednesda*.'There'is'a'changeo2er'and'the'small'tractors'are'made' ednesda*'through'8rida*'morning.''A#ter'another'changeo2er'the'largest'tractors-'which'are'in'smallest' demand-'are'made'8rida*'a#ternoon.'This't*pical'unle2eled'method'creates'#our'problems:'i#'change' o2ers'are'#easible'to'ma$e'the'Dle2el'schedule<'the*'would'be'here'also'and'more'time'is'sa2ed'because' *ou'will'ne2er'get'rid'o#'all'change'o2er'time.'I#'I'$now'the'order'due'dates'#or'the'one-'then'I'do'#or'the' other''and'I'will'produce'more-'with'better'5ualit*'with'the'#irst'line.'This'is'the'problem'with'lean-'the*'are' not'loo$ing'at'all'o#'the'associated'costs-'the*'are'ta$ing'what'wor$s'in'one'place'and'sa*ing'it'will'wor$' e2er*where.'' '''''''''!ustomers'usuall*'do'not'bu*'products'predictabl*.'I#'the'customer'decides'to'bu*'the'large' tractors'earl*'in'the'wee$'the'plant'is'in'trouble.'8le)ibilit*'in'production'is'great-'but'it'has'a'cost.' Training'*our'customer'and'passing'on'enough'2alue'gained'through'lower'production'cost'to'$eep' that'customer'is'the'$e*.'' '''''''''The'ris$'o#'unsold'goods'that'must'be'$ept'in'in2entor*.'ma*be '''''''''The'use'o#'resources'is'unbalanced.'ma*be '''''''''There'is'an'une2en'demand'on'upstream'processes.'ma*be Figure 2 represents'an'e)ample'o#'mi)ed'model'le2eled'production.':*'reducing'the'changeo2er'time' and'emplo*ing'other'Lean'methods-'the'plant'is'able'to'build'the'tractors'in'an*'order'the*'want'to'on' their'mi)ed'model'assembl*'line.'The'#our'bene#its'o#'le2eling'the'schedule'is: '''''''''8le)ibilit*'to'ma$e'what'the'customer'wants'when'the*'want'it.'!an'be'e)pensi2e-'can'*ou'get'a' better'price'or'more'sales'that'generates'a'greater'pro#itMM '''''''''Heduced'ris$'o#'unsold'goods.'/erhaps ''''''''':alanced'use'o#'labor'and'machines.'Fr'not-'ha2e'to'loo$'at'what'is'used'on'what'product.' e'do' want'to'utili@e'resources'7887!TIN7LO' '''''''''1moothed'demand'on'the'upstream'processes'and'suppliers.'F2er'what'time'period'and'what'is' the'cost'and'who'gets'the'bene#it

onday Production

!uesday Production

"ednesday Production

#hangeover !hursday Production

Friday Production

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'' Figure 1$ !raditional Production''two'change'o2ers '' onday Production

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change over !uesday Production

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Figure 2$ Leveled Production %3'change'o2ers'or'the*'ha2e'created'three'lines-'each'producing'all'da*

To'achie2e'the'bene#its'o#'continuous'#low-'companies'must'le2el'out'the'wor$load.' #ei"unka will'eliminate' waste'b*'le2eling'*our'product'2olume'and'mi)-'but'most'importantl*-'will'le2el'out'the'demand'on'*our' people-'e5uipment-'and'suppliers.' ithout'le2eling-'waste'will'increase'as'people'are'dri2en'to'wor$'li$e' mad'and'then'stop'and'wait-'>ust'li$e'the'hare.'Are'*ou'going'to'do'this'b*'building'8,'in2entor*'or' restricting'when'people'come'in-'sorr*'come'bac$'#or'lunch'at'3:30((((( #lick here to'subscribe'to'our'#ree'e-newsletter'$earnin% to $ean and'recei2e'three'articles'li$e'this'one' each'month.

'A%out the Author

'''''''9a2id'"c:ride'is'co-#ounder'o#'7"1'!onsulting',roup'4http://www.emsstrategies.com6-' &idoka-'as'practiced'at'To*ota'has'se2eral'meanings.'It'ma*'mean'Pautomation'with'human'intelligenceP'' 4&utonomation6.'Bido$a'also're#ers'to'the'practice'o#'sto''ing a (anual line or 'rocess when so(ething goes a(iss$'

Autono(ation )&idoka*
In'one'#orm-'Bido$a'uses'limit'switches'or'de2ices'that'shut'down'a'process'when: The're5uired'number'o#'pieces'ha2e'been'made.' A'part'is'de#ecti2e' The'mechanism'>ams.'

!he 'ur'ose is to free e+ui'(ent fro( the necessity of constant hu(an attention, se'arate 'eo'le fro( (achines and allow workers to staff (ulti'le o'erations$ This'#orm'o#'Bido$a'relates'closel*'to' 1higeo'1hingoAs'concept'o#'/o$a*o$e.

Line ,to' &idoka

Bido$a-'as'applied'to'manned'operations-'re#ers'to'the'practice'o#'stopping'the'entire'line'or'process'when' something'goes'amiss.'!his has i('ortant 'sychological and 'ractical effects that contri%ute greatly to -continuous .('rove(ent$-'

!he #onfusion /ver &idoka

Taiichi'Fhno'considered'Bido$a'one'o#'the'two'pillars'o#'the'To*ota'/roduction'1*stem'4T/16.'Oet'this' aspect'o#'T/1'is'mostl*'ignored'in'the' est.' hen'it'is'discussed-' there is a lot of confusion and (isunderstanding$ There'are'se2eral'reasons-'among'them: Bapanese'language'4at'least'in'e2er*da*'usage6'seems'less'precise'than'7nglish'and'the' several (eanings of &idoka do not translate well$' 8or'historical'reasons-'the autono(ation conce't see(s less relevant today'and'more'li$e'ordinar*' good'sense'and'practice.'

The'line-stoppage'2ersion'o#'Bido$a're5uires'a'strong sto(ach and 'urity of (ind that'#ew' managers'4Bapanese'or'American6'possess.' The'original'meaning'o#'Bido$a'was'PAutomationP'>ust'as'in'7nglish.'It'was'written'in' Ian>i'as'shown.'' The'Iamigo'7ngine'/lant'de2eloped'man*'stoppage'de2ices'to'halt'automated' machines.'This'became'the'word'PAutonomationP.'It'was'pronounced'as'Bido$a'but' the'Ian>i'had'a'subtle'di##erence--'the'addition'o#'a'#ew'stro$es'representing' humans'or'people.'' Later-'the'idea of sto''ing everything when so(ething went wrong was transferred to (anual asse(%ly and'the'PBido$aP'term'trans#erred'as'well.'

0eferences
"F+97+-'OA1.;IHF-'To*ota'/roduction'1*stem-'Third'7dition-'Industrial'7ngineering'3'"anagement'/ress-'Atlanta-',eorgia-'.1A-'?99&. ;AHHI"A+-'8H79-'www.#redharriman.com/ser2ices/glossar*/>ido$a.html-'%000. F;+F-'TAII!;I-'To*ota'/roduction'1*stem-':e*ond'Large'1cale'/roduction-'/roducti2it*'/ress-'?9&&.

http://www.strategosinc.com/>ido$a.htm''%/%009
1one control: Laying the foundation for lean success 2ividing the 'rocess u' and giving control3res'onsi%ility to a 'erson Todd Bennett president, United Southern Industries, and Sam McPherson, lean enterprise and public sector consultant, Shingo Prize The'#oundation'o#'the';ouse'o#'the'To*ota'/roduction'1*stem'is'J1tabilit*'in'the'E'"s'4man-'machine-'methods'and'materials6.K'Qone'control'is'To*ota<s'little-understood' territorial'management's*stem'that'pro2ides'machine-intensi2e'operations'the'same'brea$through'per#ormance'that'cellular'manu#acturing'pro2ides'assembl*'operations.'Qone' control'is'a'Jse2ere'wa*K-'but'it'was'the'method'#or'.nited'1outhern'Industries'to'achie2e'basic'stabilit*'in'its'machine-intensi2e'custom'in>ection-molding'operation.'9uring'this' session-'.1I'president'Todd':ennett'and'lean'enterprise'trans#ormation'sensei'1am'"c/herson'will'share'how'to:'organi@e'*our'operations'#or'@one'control='organi@e'@one' control<s'Jchain'o#'responsibilit*K='organi@e'the'Jchain'o#'responseK'protocols='create'@one'leader'roles'and'responsibilities='set'progressi2e'1"AHT'goals'#or'@ones='and'de2elop' @one'cadence'management'acti2ities'and'@one'leader'standard'wor$'in'support'o#'@one'control.

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A4 'ro%le( solving: si('licity at work 2e(ing5s P2#A Plan do check act cycle or ,i6 sig(a5s 2 A.# define (easure analy7e i('rove control or 2 A28 define (easure analy7e design verify on one 'iece of 'a'er

The'A3'problem-sol2ing'method'and'document-'in'combination'with'the'2alue'stream'map'4N1"6'process' #low'diagram-'a'true'N1"'onl*'lists'the'2alue'added'steps-'both'borrowed'#rom'practices'o#'the'To*ota' "otor'!ompan*-R'ha2e'shown'their'2alue'in'reducing'waste'and'error.'The'A3'method'o##ers'a'longmissing'standardi@ed'approach'to'sol2ing'problems'identi#ied'in'higher-le2el'2alue'stream'maps. h*'is'the'method'called'A3M'In'7urope-'the'nearest'metric'e5ui2alent'to'??P')'?GP'paper'is'designated' PA3.P'The'method'con#ines'a'team'to'what'will'#it'on'that'si@e'sheet'o#'paper-'#orcing'simplicit*'and'5uic$' communication.'This'assures'the'wor$'can'be'realisticall*'completed'within'this'constraint.'It' demonstrates'success#ul'change'and'moti2ates'wor$ers'to'do'e2en'more'problem'sol2ing.';igh'le2el'and' then'drill'down-'each'acti2it*'on'an'A3'could'ha2e'another'A3 !he A4 is o%jective and safe The'N1"'gi2es'the'user'a'P?0-000-#oot'le2elP'2iew'o#'the'current'steps'in'a'process'#rom'the'point'o#' re5uest'to'deli2er*'o#'what'was're5uested.'9ata'collected'in'each'o#'the'steps'or'Pprocess'bo)esP'show' statisticall*'4thus-'ob>ecti2el*6'where'there'is'2ariation.'This'#lags'which'acti2ities'within'the'step'to'

obser2e'and'remo2e'barriers'the'wor$er'must'wor$'around.'These'wor$-arounds'and'rewor$'are'what'the' A3'process'helps'ma$e'2isible-'impro2ing'the'2alue'stream'as'a'result. The'A3'is'a'wa*'to'loo$'with'Pnew'e*esP'at'a'speci#ic'problem'identi#ied'b*'direct'obser2ation'or' e)perience.'It'o##ers'a'structure'that'alwa*s'begins'b*'de#ining'the'issue'#rom'the'customerAs'perspecti2e.' 1tating'the'problem'this'wa*'ma$es'its'resolution'indisputable.'A#ter'all-'wh*'are'we'all'here'i#'not'to' produce'an'ideal'ser2ice'or'product'#or'the'customerM Fb>ecti2it*'is'#urther'rein#orced'b*'creating'a'deep'understanding'o#'the'current'condition'be#ore'>umping' to'a'solution.' hen'we'obser2e'and'diagram'the'current'condition-'we'2isuall*'represent'how'the'current' process'wor$s.' e'recogni@e'wea$ness'in'the'process-'not'in'the'people'tr*ing'to'use'the'bro$en' process.'conceptual'model'will'contain'this'in#ormation Fnce'we'construct'that'#irst'2iew'o#'the'problem'and'2alidate'it'with'the'people'doing'the'wor$-'we'can' mo2e'on'to'as$-'P hat'is'not'ideal'about'the'wa*'this'wor$'is'happeningMP'There'is'so'much'power'in' gaining'a'deep'understanding'o#'the'wa*'the'wor$'is'currentl*'done-'*et'we'ha2e'not'alwa*s'ta$en'the' time'to'obser2e'and'understand'a'process'be#ore'#i)ing'it.' ith'a'deep'understanding-'there'is'a' tremendous'opportunit*'to'loo$'at'wor$'di##erentl*'and'reall*'see'the'opportunities'#or'impro2ement.'The' A3'gi2es'us'a'new'wa*'to'loo$'at'wor$. 2iagra(s and si('le gra'hics contri%ute to a dee'er understanding

!lic$'on'the'image'to'enlarge.'

ith'the'simple'graphic'representation'o#'a's*stem'problem'in'the'current'condition-'the'problem-sol2er' can'o#ten'see'redundant'wor$'5uic$l*'and'clearl*-'and'share'the'reali@ation'with'others'in2ol2ed'in' resol2ing'the'issue.' 1tic$-#igure'drawings'with'lines'and'arrows'demonstrate'loops'in'wor$'that'create'wor$-arounds'and' rewor$.'9rawing'storm'clouds'shows'where'problems'reside.' .sing'pencil'ma$es'it'sa#e'#or'a'problem-sol2er'to'ta$e'the'drawing'to'others'and'sa*-'P;ere'is'm*' understanding'o#'how'this'wor$'happens'now0did'I'get'it'rightM'Are'there'steps'I'ma*'ha2e'le#t'outMP'All' in2ol2ed'can'erase-'redraw'and'correct'an*'wrong'assumptions'that'ma*'ha2e'been'made'about'the' wor$.'!hanges'can'be'made'immediatel*-'so'problem'sol2ing'is'rapid'and'accurate-'and'wor$ers'can' participate'in'creating'the'essential'understanding. !he A4 offers a si('le and consistent way to achieve and docu(ent root cause analysis To'get'to'the'root'cause'o#'the'problems'#lagged'with'storm'clouds-'To*otaAs'P5' h*'been'around'longer' than'To*ota-'howe2er-'the*'ha2e'it'embedded'in'their'cultureMP'approach'is'eas*'to'remember'and'

e)ecute.' hen'the'#inal'P h*MP're2eals'the'root'cause-'we'$now'what'must'be'addressed'to'mo2e'the' process'closer'to'the'ideal'state.'The'#inal'P h*MP'in'the'anal*sis'o#'each'storm'cloud/problem'creates'a' chec$list'o#'what'to'do'in'the'implementation'plan'not'that'eas*-'as'man*'times'the'#inal'wh*'is'a'cultural' or'belie#'issue'held'b*'a'high'le2el'decision'ma$er.' #reating the target condition is easy once you get your (odel validated, then one can (ove to this stage The'right'side'o#'the'page'is'the'creati2e'and'#un'hal#'o#'the'A3.'It'is'entered'into'with'such'a'deep' understanding'o#'the'current'wor$'that'a'better'wa*'comes'easil*.' e'should'see'the'simpler-'cleaner' process'appear'on'paper-'in'pencil'again-'with'#ewer'rewor$'loops'and'wor$-arounds.' :ecause'we'did'the'in2estigati2e'wor$'on'the'#irst'hal#'o#'the'A3-'it'is'eas*'to'compare'the'target'condition' to'the'current'condition'and'as$-'P9oes'the'proposed'wa*'to'wor$'mo2e'us'closer'to'idealMP'I#'the'answer' is'*es-'we'can'mo2e'#orward'to'de#ining'countermeasures'and'changes'we'need'to'ma$e'to'mo2e'the' process'#rom'the'current'to'the'target'condition.'In'practice'man*'decisions'are'made'with'point'estimates' deri2ed'#rom'using'deterministic'2alues-'thus-'the'answer'is'wrong.'I#'there'are'stochastic'2ariables-'their' distributions'must'be'included'and'a'!I'de2eloped'to're#lect'the'underl*ing'ris$s'o#'the'decision.'' Accounta%ility occurs naturally :*'de#ining'what'needs'to'happen-'b*'whom-'b*'when'and'with'what'e)pected'outcome-'we'2er*'clearl*' and'realisticall*'speci#*'the'wor$'#or'the'problem-sol2ers'in2ol2ed.'This'is'our'wor$'list'--'how'the'A3' author'or'team'can'chec$'progress.':ecause'it'speci#ies'the'wor$-'e2er*one'in2ol2ed'$nows'e)actl*' whatAs'e)pected'o#'him'or'her.' e'can're#er'bac$'to'the'root'causes'shown'on'the'le#t'side'o#'the'A3'and' as$'oursel2es-'P;a2e'we'remo2ed'the'causes'$eeping'us'#rom'achie2ing'the'target'conditionMP !esting esta%lishes a safe, e6'eri(ental attitude and environ(ent It'is'important'to'simulate'the'process'or'set'up'a'test'en2ironment'to'challenge'and'e)perience'the' proposed'process.'The'test-'with'a'de#ined'timeline-'ma$es'it'sa#e'#or'problem-sol2ers'to'be'creati2e'and' e)periment.'Although'the'deep'understanding'achie2ed'earlier'ma$es'ris$'minimal-'testing'allows'us'to' twea$'the's*stem'be#ore'implementation.'Fnce'the'test'is'done'and'implementation'is'authori@ed-'the' newl*'designed'wor$'can'proceed.' Hesponsibilit*'#or'#ollow-up'assessments'o#'the'new'process'on'speci#ic'dates'noted'on'the'A3'is' assigned'to'one'or'more'indi2iduals.'The'#ollow-up'report'becomes'the'new'current'condition.'I#'itAs'not' per#ect-'thatAs'FI(' e'initiate'another'A3'and'as$'again-'P hat'isnAt'ideal'about'our'new'current' conditionMP'The'c*cle'generates'ongoing'adaptation'to'the'ine2itable'changes'in'our'wor$.' This'again'demonstrates'the'Psa#et*P'o#'the'A3'process='an'A3'is'deemed'success#ul'i#'the'e##orts'mo2ed' us'closer'to'ideal-'e2en'i#'we'did'not'achie2e'e2er*thing'we'wanted.'+o'one'is'chastised'#or'not'ma$ing'it' per#ect'on'the'#irst'round. anage(ent and staff learn to see 'ro%le(s the sa(e way hen'sta##'and'management'ha2e'e)perienced'the'A3'process'and'an'issue'arises'#or'which'the'A3' approach'is'suggested-'e2er*one'$nows'the'steps'that'will'be'emplo*ed-'belie2es'that'the*'will'be'either' in2ol2ed'or'represented'in'the'wor$'redesign'and'that'there'will'be'a'timeline'and'accountabilit*'#or' completion.'The*'belie2e'that'the'e)perimental'en2ironment'will'be'sa#e.'The*'$now'that'when'problem' sol2ing'is'reported-'it'will'be'consistent'and'eas*'to'understand.' hen'management'sa*s-'PI'thin$'we' should'do'an'A3'on'this-P'e2er*one'$nows'what'that'means. A4 'ro%le( solving occurs as 'art of everyday work Large'numbers'o#'sta##'do'not'ha2e'to'be'gathered'#or'e)tended'times'to'do'speculati2e'problem'sol2ing.' !oaches'can'be'recogni@ed'and'easil*'trained'to'help'sta##'2alidate'and'participate'in'the'A3'process' without'lea2ing'the'wor$place. A4 'ro%le( solving is intuitive and easy to learn and re(e(%er "ost'emplo*ees'are'not'engineers'or'process-impro2ement'specialists.'The'A3'process'is'logical'thin$ing'

based'on'the'scienti#ic'method'o#'problem'sol2ing.'It'is'eas*'to'learn'and'teach'and're5uires'no'technical' training. A4 thinking (eans %etter and fewer (eetings !onducting'a'lean'meeting'using'the'A3'process'can'greatl*'reduce'the'time'and'numbers'o#'meetings' re5uired.'A3s'are'best'done'b*'a'group'o#'two'to'#i2e'people'representing'the'a##ected'parties.'These' people'procure'2alidation'o#'the'current'condition'and'the'target'condition'#rom'peers.' !he A4 'rocess docu(ents costs and %enefits The'cost'o#'the'implementation'plan'is'documented'on'e2er*'A3'and'can'be'compared'to'the'bene#it.'It' can're#lect'hard'or'so#t'dollars'sa2ed-'or'be'a'measure'o#'5ualit*'o#'ser2ice.'This'creates'ob>ecti2e' in#ormation'#or'leadership'to'use'in'authori@ing'the'implementation'plan'presented'on'the'A3'document. !he A4 te('late hel's us solve 'ro%le(s and docu(ent new 'rocesses hen'the'A3'document'is'$ept'in'a'three-ring'binder-'acti2ities'can'be're2iewed'b*'auditors'or'regulator*' groups-'senior'leaders-'and'sta##'#rom'other'departments.'This'promotes'cross-departmental'sharing'o#' process'changes'and'generates'e2en'more'problem-sol2ing'ideas.' !he A4 'rocess is satisfying to everyone, 'articularly frontline workers The'A3'is'eas*'to'learn'and'eas*'to'teach.'1ta##'can'use'it'to'remo2e'the'#rustrations'o#'their'dail*'wor$' created'b*'wea$'and'unsupporti2e'processes.':eing'in2ol2ed'with'creating'a'better'wa*'to'wor$'has'been' e)ceptionall*'well'recei2ed'b*'#rontline'wor$ers-'who'To*ota'recogni@es'as'the'resident'e)perts'in'an*' industr*.' or$ers'can'see'and'appreciate'the'changes'the*'participated'in'creating.'In'this'era'o#'current' and'impending's$illed-wor$er'shortage-'satis#action'is'essential'to'retaining'good'emplo*ees.' !ind*'Bimmerson'can'be'reached'at'Lean';ealthcare' est'in'"issoula-'"ontana'at' cind*Sleanhealthcarewest.com. Rhttp://www.lean.org Ianban

9an%an'4in'$an>i''also'in'$ata$ana'-'where'kan,''-'means' P2isual-P'and'ban,''-'means'PcardP'or'PboardP6'is'a'concept'related'to'lean'and' >ust-in-time'4BIT6'production.'The'Bapanese'word'kanban'4pronounced'[kamba]6'is'a' common'e2er*da*'term'meaning'PsignboardP'or'PbillboardP'and'utterl*'lac$s'the' speciali@ed'meaning'that'this'loanword'has'ac5uired'in'7nglish.'According'to'Taiichi' Fhno-'the'man'credited'with'de2eloping'BIT-'$anban'is'a'means'through'which'BIT'is' achie2ed.T%U Ianban'is'a'signaling's*stem'to'trigger'action.'As'its'name'suggests-'$anban' historicall*'uses'cards'to'signal'the'need'#or'an'item.';owe2er-'other'de2ices'such' as'plastic'mar$ers'4$anban's5uares6'or'balls'4o#ten'gol#'balls6'or'an'empt*'parttransport'trolle*'or'#loor'location'can'also'be'used'to'trigger'the'mo2ement-' production-'or'suppl*'o#'a'unit'in'a'#actor*. It'was'out'o#'a'need'to'maintain'the'le2el'o#'impro2ements'that'the'$anban's*stem' was'de2ised'b*'To*ota.'Ianban'became'an'e##ecti2e'tool'to'support'the'running'o#' the'production's*stem'as'a'whole.'In'addition-'it'pro2ed'to'be'an'e)cellent'wa*'#or'

promoting'impro2ements'because'reducing'the'number'o#'$anban'in'circulation' highlighted'problem'areas.T3U
51

:,'is'a're#erence'to'a'list'o#'#i2e'Bapanese'words'which-'translated'into'7nglish-'start' with'the'letter'1'and'are'the'name'o#'a'methodolog*.'This'list'is'a'mnemonic'#or'a' methodolog*'that'is'o#ten'incorrectl*'characteri@ed'as'Pstandardi@ed'cleanupP-' howe2er'it'is'much'more'than'cleanup.'51'is'a'philosoph*'and'a'wa*'o#'organi@ing' and'managing'the'wor$space'and'wor$'#low'with'the'intent'to'impro2e'e##icienc*' e##ecti2eness'b*'eliminating'waste-'impro2ing'#low'and'reducing'process' unreasonableness. TeditU'

hat'is'51M'or'/A!/!'or'5!'clear'out-'con#igure-' clean'and'chec$-'con#ormit*-'custom'and'practice
51'is'a'method'#or'organi@ing'a'wor$place-'especiall*'a' shared'wor$place'4li$e'a' shop'#loor'or'an'o##ice'space6-'and'$eeping'it'organi@ed.'ItAs'sometimes're#erred'to' as'a'house$eeping'methodolog*-'howe2er'this'characteri@ation'can'be'misleading' because'organi@ing'a'wor$place'goes'be*ond'house$eeping'4see'discussion'o#' P1eitonP'below6. The'$e*'targets'o#'51'are'wor$place'morale'and'e##icienc*.'The'assertion'o#'51'is-' b*'assigning'e2er*thing'a'location-'time'is'not'wasted'b*'loo$ing'#or'things.' Additionall*-'it'is'5uic$l*'ob2ious'when'something'is'missing'#rom'its'designated' location.'51'ad2ocates'belie2e'the'bene#its'o#'this'methodolog*'come'#rom'deciding' what'should'be'$ept-'where'it'should'be'$ept-'and'how'it'should'be'stored.'This' decision'ma$ing'process'usuall*'comes'#rom'a'dialog'about'standardi@ation'which' builds'a'clear'understanding-'between'emplo*ees-'o#'how'wor$'should'be'done.'It' also'instills'ownership'o#'the'process'in'each'emplo*ee. In'addition'to'the'abo2e-'another'$e*'distinction'between'51'and'Pstandardi@ed' cleanupP'is'1eiton.'1eiton'is'o#ten'misunderstood-'perhaps'due'to'e##orts'to'translate' into'an'7nglish'word'beginning'with'P1P'4such'as'PsortP'or'PstraightenP6.'The'$e*' concept'here'is'to'order'items'or'acti2ities'in'a'manner'to'promote'wor$'#low.'8or' e)ample-'tools'should'be'$ept'at'the'point'o#'use-'wor$ers'should'not'ha2e'to' repetiti2el*'bend'to'access'materials-'#low'paths'can'be'altered'to'impro2e' e##icienc*-'etc. The'51As'are: /hase'?'-',eiri'461orting:',oing'through'all'the'tools-'materials-'etc.-'in'the'plant' and'wor$'area'and'$eeping'onl*'essential'items.'72er*thing'else'is'stored'or' discarded.

/hase'%'-',eiton'461traighten'or'1et'in'Frder:'8ocuses'on'e##icienc*.' hen'we' translate'this'to'P1traighten'or'1et'in'FrderP-'it'sounds'li$e'more'sorting'or'sweeping-' but'the'intent'is'to'arrange'the'tools-'e5uipment'and'parts'in'a'manner'that'promotes' wor$'#low.'8or'e)ample-'tools'and'e5uipment'should'be'$ept'where'the*'will'be'used' 4i.e.'straighten'the'#low'path6-'and'the'process'should'be'set'in'an'order'that' ma)imi@es'e##icienc*. /hase'3'-',eis;'461weeping:'1*stematic'!leaning'or'the'need'to'$eep'the' wor$place'clean'as'well'as'neat.'9ail*'acti2it*'at'the'end'o#'each'shi#t-'the'wor$'area' is'cleaned'up'and'e2er*thing'is'restored'to'its'place-'ma$ing'it'eas*'to'$now'what' goes'where'and'to'$now'when'e2er*thing'is'where'it'should'be'are'essential'here.' The'$e*'point'is'that'maintaining'cleanliness'should'be'part'o#'the'dail*'wor$'-'not'an' occasional'acti2it*'initiated'when'things'get'too'mess*. /hase'E'-',eiketsu'461tandardising:'1tandardi@ed'wor$'practices'or'operating' in'a'consistent'and'standardi@ed'#ashion.'72er*one'$nows'e)actl*'what'his'or'her' responsibilities'are. /hase'5'-',hitsuke'461ustaining:'He#ers'to'maintaining'and're2iewing'standards.' Fnce'the'pre2ious'E1As'ha2e'been'established'the*'become'the'new'wa*'to' operate.'"aintain'the'#ocus'on'this'new'wa*'o#'operating-'and'do'not'allow'a'gradual' decline'bac$'to'the'old'wa*s'o#'operating.';owe2er-'when'an'issue'arises'such'as'a' suggested'impro2ement'or'a'new'wa*'o#'wor$ing-'or'a'new'tool-'or'a'new'output' re5uirement'then'a're2iew'o#'the'#irst'E1As'is'appropriate.

:, Housekee'ing < to organi7e the work'lace ,ort''/ut'selected'

things'in'order' 41eiri6 1tart'b*'sorting'the'use#ul'#rom'the'unnecessar*.' The'onl*'things'that'should'remain'in'a'wor$'area' are'the'parts-'tools-'3'instructions'needed'to'do' the'>ob.' 72er*thing'has'a'place='e2er*thing'is'in'its'place.

,traighten''
Arrange'41eiton6

This'is'also'a'good'time'#or'*our'team'to'create'a' Nisual'1coreboard-'Bido$a'lights-'#loor'paint-' $anbans-'and'other'2isual'controls'described'in' our'our'#ree'Lean'3'Iai@en'/ower/oint' presentation. 9o'an'initial'spring'cleaning.' "a*be'painting-'scouring-'sweeping-'washing-'

,wee''=',hine'

!lean'41eiso6

rinsing-'scrubbing-'and'whate2er'else'is'needed' to'ma$e'*our'wor$'place'shine. In'the'1tandardi@e'phase'o#'Lean'5'1-'routine' cleaning'becomes'a'wa*'o#'li#e.'

,tandardi7e'
41ei$etsu6'/urit*'o#' s*stems'so'ne2er'brea$' down

/re2entati2e'maintenance'is'routinel*'per#ormed-' perhaps'with'planning'and'scheduling'and'some' responsibilities'done'b*'*our'central'maintenance' department-'and'as'much'routine'maintenance'as' possible'per#ormed'b*'the'people'that'$now'that' wor$'center'better'than'an*one'else. 1hitsu$e'is'when''#i2e'1'becomes'a'routine'wa*' o#'li#e.'Hoot'causes'are'routinel*'identi#ied'and' dealt'with.'The'1*stems%win'7)cel'templates' $nown'as'the'51' or$sheet'and'the'1tandard' or$'Audit'are'2er*'#amiliar'to'e2er*one'-'both' super2isors'and'the'wor$ers'that'ha2e'come'to' appreciate'the'bene#its'o#'8i2e'1'and'Lean' methods. 1ome'companies'ha2e'ta$en'to'calling'their' program'a'61'program'-'with'the'inclusion'o#' 1a#et*'issues.'The'1*stems%win'51'1corecard' template'does'include'a'section'#or'sa#et*.

,ustain'
41hitsu$e6'!ommitment

,afety'
T/"

What is TPM?
>uick 2efinition T/"'4Total'/roducti2e'"aintenance6'is'a'maintenance'philosoph*'designed'to'integrate' e5uipment'maintenance'into'the'manu#acturing'process.'The'goal'o#'an*'T/"'program' is'to'eliminate'losses'tied'to'e5uipment'maintenance'or-'in'other'words-'$eep'e5uipment' producing'onl*'good'product-'as'#ast'as'possible'with'no'unplanned'downtime.';ow' does'this'translate'to'people'4mental'and'ph*sical'pre2enti2e'maintenance-'washing' hands'and'touched'sur#aces-'not'coming'into'wor$'sic$006 ?6'anded 2efinition

"aintenance'has'traditionall*'been'2iewed'as'a'separate'entit*'outside'o#'the' manu#acturing'process.'As'companies'began'to'identi#*'the'role'o#'maintenance'in'the' production'process'a'gradual'shi#t'in'thin$ing'occurred.'T/"'emerged'out'o#'the'need'to' integrate'maintenance'with'manu#acturing'to'impro2e'producti2it*'and'asset'a2ailabilit*.' The'culmination'o#'change'#rom'a'reacti2e/correcti2e'maintenance'en2ironment'to'one' that'is'based'on'pre2entati2e'maintenance'through'predicti2e'maintenance'is'the' process'o#'T/". T/"'is'used'to'dri2e'waste'out'o#'the'manu#acturing'process'b*'reducing'or'eliminating' production'time'lost'to'machine'#ailures.'The'goal'o#'an*'T/"'program'is'to'ensure'that' machiner*'and'e5uipment'is'alwa*s'a2ailable'to'manu#acture'products'#or'the'end' customer.':*'minimi@ing'rewor$-'slow'running'e5uipment'and'downtime-'ma)imum' 2alue'is'added'at'the'minimum'cost. 1uccess#ul'T/"'is'a'group'e##ort'where'the'entire'organi@ation'wor$s'together'to' maintain'and'impro2e'the'e5uipment.'Fne'o#'the'#irst'steps'in'implementing'T/"'is' #orming'cross'#unctional'teams'that'are'empowered'to'impro2e'the'process.'8lattening' the'organi@ational'structure'enables'teams'to'address'issues'when'the*'ha2e'the' greatest'impact'-'when'the*'occur.'As'emplo*ees'>oin'T/"'teams-'operators'are'trained' to'per#orm'routine'maintenance'items'and'assume'an'ownership'role.'7mplo*ees' empowered'to'a##ect'the'process'will't*picall*'be'in'a'position'to'identi#*'and'create' process'impro2ements'that'would'ha2e'normall*'been'o2erloo$ed'b*'management.'An' on-going're#actoring'o#'the'process'pro2ides'a'method'to'implement'impro2ements. As'maintenance'issues'are'addressed'and'total'producti2e'maintenance'programs' implemented-'the'true'2alue'o#'T/"'begins'to'emerge.'Bust'as'lean'manu#acturing' relies'on'Iai@en'or'continuous'impro2ement='continuous're-e2aluation'o#'the' maintenance'c*cle'allows'#or'$ai@en'in'maintenance'programs.'Hoot'cause'anal*sis' e)poses'the'underl*ing'issues'to'be'addressed.':*'addressing'issues'at'the'root'le2el-' problems'can'be'eliminated. As'with'an*'lean'initiati2e'it'is'critical'to'measure'change.'F77'4F2erall'75uipment' 7##ecti2eness6'is'a'metric'originall*'de2eloped'to'measure'the'success'o#'total' producti2e'maintenance'programs'b*'associating'the'1i)':ig'Losses'with'three' measurables:'A2ailabilit*-'/er#ormance'and'Cualit*.'F77'enables'organi@ations'to' benchmar$'and'monitor'their'progress'with'simple-'eas*'to'understand'metrics.'F77' pro2ides'both'a'gauge'#or'the'success'o#'T/"'and'a'#ramewor$'to'identi#*'areas'that' can'be'impro2ed.
Six Big Loss Category
Breakdowns

OEE Loss Category

9own'Time' Loss

Event Examples
Tooling Failures Unplanned Maintenance General Breakdowns Equipment Failure

Comment

There'is'#le)ibilit*'on'where'to'set'the' threshold'between'a':rea$down' 49own'Time'Loss6'and'a'1mall'1top' 41peed'Loss6.

Setup and Adjustments

9own'Time' Loss

Setup/Changeover Material Shortages perator Shortages Ma!or "d!ustments #arm$Up Time %structed &roduct Flow Component 'ams Mis(eeds Sensor Blocked )eliver* Blocked Cleaning/Checking +ough +unning Under ,ameplate Capacit* Under )esign Capacit* Equipment #ear perator -ne((icienc* Scrap +ework -n$&rocess )amage -n$&rocess E.piration -ncorrect "ssem%l* Scrap +ework -n$&rocess )amage -n$&rocess E.piration -ncorrect "ssem%l*

This'loss'is'o#ten'addressed'through' setup'time'reduction'programs.

Small Stops

1peed'Loss

T*picall*'onl*'includes'stops'that'are' under'#i2e'minutes'and'that'do'not' re5uire'maintenance'personnel.

Reduced Speed

1peed'Loss

An*thing'that'$eeps'the'process'#rom' running'at'its'theoretical'ma)imum' speed'4a.$.a.'Ideal'Hun'Hate'or' +ameplate'!apacit*6. He>ects'during'warm-up-'startup'or' other'earl*'production.'"a*'be'due'to' improper'setup-'warm-up'period-'etc.

Startup Rejects

Cualit*'Loss

Production Rejects

Cualit*'Loss

He>ects'during'stead*-state' production

,i6 Big Losses

2efining the ,i6 Big Losses Fne'o#'the'ma>or'goals'o#'T/"'and'F77'programs'is'to'reduce'and/or'eliminate'what' are'called'the',i6 Big Losses'V'the'most'common'causes'o#'e##icienc*'loss'in' manu#acturing.'The'#ollowing'table'lists'the'1i)':ig'Losses-'and'shows'how'the*'relate' to'the'F77'Loss'categories.

Six Big Loss Category

OEE Loss Category

Event Examples Tooling Failures Unplanned Maintenance General Breakdowns Equipment Failure

Comment

Breakdowns 9own'
Time'Loss

There'is'#le)ibilit*'on' where'to'set'the' threshold'between'a' :rea$down'49own'Time' Loss6'and'a'1mall'1top' 41peed'Loss6.

Setup and 9own' Adjustments Time'Loss

This'loss'is'o#ten' addressed'through' Shortages setup'time'reduction' Ma!or "d!ustments programs.

#arm$Up Time %structed &roduct Flow Component 'ams Mis(eeds Sensor Blocked )eliver* Blocked Cleaning/Checking +ough +unning Under ,ameplate Capacit* Under )esign Capacit* Equipment #ear perator -ne((icienc* Scrap +ework -n$&rocess )amage -n$&rocess E.piration

Setup/Changeover Material Shortages perator

Small Stops

1peed' Loss

T*picall*'onl*'includes' stops'that'are'under'#i2e' minutes'and'that'do'not' re5uire'maintenance' personnel.

Reduced Speed

1peed' Loss

An*thing'that'$eeps'the' process'#rom'running'at' its'theoretical'ma)imum' speed'4a.$.a.'Ideal'Hun' Hate'or'+ameplate' !apacit*6.

Startup Rejects

Cualit*' Loss

He>ects'during'warm-up-' startup'or'other'earl*' production.'"a*'be'due' to'improper'setup-' warm-up'period-'etc.

-ncorrect "ssem%l* Scrap +ework -n$&rocess )amage -n$&rocess E.piration

Production Rejects

Cualit*' Loss

He>ects'during'stead*state'production.

-ncorrect "ssem%l*

Addressing the ,i6 Big Losses +ow'that'we'$now'what'the'1i)':ig'Losses'are'and'some'o#'the'e2ents'that'contribute'to'these' losses-'we'can'#ocus'on'wa*s'to'monitor'and'correct'them.'!ategori@ing'data'ma$es'loss' anal*sis'much'easier-'and'a'$e*'goal'should'be'#ast'and'e##icient'data'collection'wor$#low'

solutions'that'automaticall*'collect'data-'with'data'put'to'use'throughout'the'da*'and'in'realtime.' Breakdowns 7liminating'unplanned'2own !i(e'is'critical'to'impro2ing'F77.'Fther'F77'8actors'cannot'be' addressed'i#'the'process'is'down.'It'is'not'onl*'important'to'$now'how'much'9own'Time'*our' process'is'e)periencing'4and'when6'but'also'to'be'able'to'attribute'the'lost'time'to'the'speci#ic' source'or'reason'#or'the'loss'4tabulated'through'0eason #odes6.' ith'9own'Time'and' Heason'!ode'data'tabulated-'0oot #ause Analysis'is'applied'starting'with'the'most'se2ere' loss'categories. Setup and Adjustments 1etup'and'Ad>ustment'time'is'generall*'measured'as'the'time'between'the'last'good'part' produced'be#ore'1etup'to'the'#irst'consistent'good'parts'produced'a#ter'1etup.'This'o#ten' includes'substantial'ad>ustment'and/or'warm-up'time'in'order'to'consistentl*'produce'parts'that' meet'5ualit*'standards.'/re-control'a#ter'each'set'up'is'o#ten'necessar* Trac$ing',etu' !i(e'is'critical'to'reducing'this'loss-'together'with'an'acti2e'program'to'reduce' this'time'4such'as'an'1"79'-'1ingle'"inute'7)change'o#'9ies'program6.' "an*'companies'use'creati2e'methods'o#'reducing'1etup'Time'including'assembling' changeo2er'carts'with'all'tools'and'supplies'necessar*'#or'the'changeo2er'in'one'place-'pinned' or'mar$ed'settings'so'that'coarse'ad>ustments'are'no'longer'necessar*-'and'use'o#' pre#abricated'setup'gauges. Small Stops and Reduced Speed 1mall'1tops'and'Heduced'1peed'are'the'most'di##icult'o#'the'1i)':ig'Losses'to'monitor'and' record. #ycle !i(e Analysis should'be'utili@ed'to'pinpoint'these'loss't*pes.'In'most'processes' recording'data'#or'!*cle'Time'Anal*sis'needs'to'be'automated'since'c*cles'are'5uic$'and' repetiti2e'e2ents'that'do'not'lea2e'ade5uate'time'#or'manual'data-logging.' :*'comparing'all'completed'c*cles'to'the'Ideal'!*cle'Time'and'#iltering'the'data'through'a' 1mall'1top'Threshold'and'Heduced'1peed'Threshold'the'errant'c*cles'can'be'automaticall*' categori@ed'#or'anal*sis.'The'reason'#or'anal*@ing'1mall'1tops'separatel*'#rom'Heduced' 1peed'is'that'the'root'causes'are't*picall*'2er*'di##erent-'as'can'be'seen'#rom'the'72ent' 7)amples'in'the'pre2ious'table. Startup Rejects and Production Rejects 1tartup'He>ects''and'/roduction'He>ects'are'di##erentiated-'since'o#ten'the'root'causes'are' di##erent'between'startup'and'stead*-state'production.'/arts'that're5uire'rewor$'o#'an*'$ind' should'be'considered're>ects.'Trac$ing'when're>ects'occur'during'a'shi#t'and/or'>ob'run'can' help'pinpoint'potential'causes-'and'in'man*'cases'patterns'will'be'disco2ered.' F#ten'a',i6 ,ig(a'program-'where'a'common'metric'is'achie2ing'a'de#ect'rate'o#'less'than'3.E' de#ects'per'million'3.E'million'is'accounting'#or'a'continuous'?.5'standard'de2iation'shi#t'#rom'

desired'target-'i#'the'target'and'mean'were'the'same'it'would'be'%/billion'opportunities' PopportunitiesP-'is'used'to'#ocus'attention'on'a'goal'o#'achie2ing'Pnear'per#ectP'5ualit*.

http://www.oee.com/oeeWsi)WbigWlosses.html Iai@en
Fther'Iai@en'"aga@ine'Articles

@etting Back to Basics

8ind'*our'mista$es'and'learn'#rom'them.'
:*'Tom'9ossenbach This'article'#irst'appeared'in' ood'3' ood'/roducts In'response'to'recent'reader'in5uiries'about'!ontinuous'Impro2ement-'I'#eel'man*'manu#acturers'need' encouragement'to'stop'loo$ing'at'this'as'some'sophisticated'management's*stem'#or'the'rich'and'#amous.'It'matters' not'that'*ou'are'a'small'shop'ma$ing'$itchen'cabinets-'a'supplier'o#'parts'to'the'industr*-'a'millwor$'compan*'or'a' 8ortune'500'compan*.'!ontinuous'impro2ement'is'#or'e2er*one. Aou have heard a lot a%out 9ai7en'4J,ood'!hangeK'or'J!ontinuous'Impro2ementK6'o2er'the'past'decade.'The' Bapanese'ha2e'been'gi2en'the'credit'#or'this'mo2ement-'but'actuall*'9r.' .'7dwards'9emming'initiated'much'o#'the' philosoph*'while'assisting'the'rebuilding'o#'Bapanese'industr*'#ollowing' orld' ar'II.':ut'regardless'o#'what'*ou'call' it-'there'are'two'important'a)ioms'to'bear'in'mind: ?.'!ontinuous'Impro2ement'e##orts-'applied'diligentl*-' will'generate'positi2e'results'--'certain( %.'9e#iance'o#'!ontinuous'Impro2ement'/ursuit' will'result'in'compan*'doom'--'certain( ,o(e of us have forgotten what we learned'man*'*ears'ago'when'we'had'suggestion'bo)es'in'our'plants.' e' learned'that'those'on'the'production'#loor'$new'better'than'an*one'what'needed'to'be'done'to'impro2e'producti2it*' and'5ualit*.'The'problem'was'that'we'reall*'did'not'ha2e'a'program'in'place'to'#ollow'up.'+ow'it'is'time'to'get'those' suggestions'out'o#'the'bo)'and'empower'emplo*ees'and'groups'o#'emplo*ees'to'participate'in'their'own'change' initiati2es'#or'the'good'o#'the'compan*.

#ontinuous .('rove(ent: "hat .s .tB

hat'is'continuous'impro2ement'and'wh*'is'it'importantM'The'answers'are'#ound'in'the'#ollowing'simple'e)ample: I'did'some'consulting'#or'a'case'goods'manu#acturer'last'*ear.'9uring'a'tour'o#'the'#actor*'I'noticed'that'there'was'a' lad*'on'the'assembl*'line'wor$ing'2er*'diligentl*'scraping'and'hand'sanding'e2er*'one'o#'the'2eneered'tops'to' remo2e'de#ects.'I'had'>ust'seen'an'e)cellent'sanding'department'with'up-to-date'e5uipment'so'I'as$ed'Albert-'the' super2isor-'wh*'the*'were'ha2ing'to'do'so'much're-wor$M ;e'replied-'We always ha'e to because o( the scratches and marks on the tops.) Where do the marks come (rom*)'I'as$ed. Well, they "ust happen.) #a'e you tried to (ind out why*) We can+t. ,t+s always somethin% -- (irst one thin% and then another). I'replied-'Well, why don+t you try to (i- the one thin%+ (irst and then the other+*) 1ure'enough-'we'too$'a'5uic$'loo$'and'#ound'the'drawer'#itter'was'using'the'top'as'a'wor$bench'#or'his'tools='the' top-out'station'dragged'one'top'across'the'other'as'the*'drew'#rom'stoc$='and'a'wet'sponge'was'set'on'another'top.'I' suggested'to'Albert'that'we'ta$e'two'minutes-'right'then-'and'e)plain'the'problem'to'the'entire'line'and'point'out' some'o#'our'obser2ations'as$ing'them'to'see'i#'the*'could'#ind'wa*s'to'a2oid'the'e)tra'wor$.

The'assemblers'began'being'more'care#ul'when'appl*ing'glue'so'there'was'no'reason'to'use'a'wet'sponge'on'the' tops'to'remo2e'the'glue.'The'top-out'station'started'li#ting'the'tops'instead'o#'dragging'them.'The'drawer'#itters' started'placing'their'tools'on'a'con2enient'shel#'the*'made.'4These'are'woodwor$ers-'a#ter'all.6'Fther'ideas'on'how'to' a2oid'dents'and'scratches'were'discussed. By the end of the ne6t day, the lady who had %een sanding the to's had %een (oved to another de'art(ent$ !hat5s a C4D,DDD cost avoidanceE The'norm'in'industr*'toda*'is'to'repair'the'damage'or'to'remo2e'the's*mptom.'That<s'what'the*'were'doing.'The' Iai@en'wa*'is'to'get'to'the'cause'and'remo2e'it-'permanentl*.'/utting'it'another'wa*-'we'o#ten'are'satis#ied'to'sa*:'JI#' it<s'bro$en-'#i)'it.K'In'a'plant'practicing'continuous'impro2ement-'the'5uestion'is:'J h*'did'it'brea$MK'This'is'how'all'o#' *ou'must'thin$'about'*our'processes'when'deciding'what'to'implement'as'impro2ements I'ha2e'said'it'be#ore'and'I'will'sa*'it'again.'Oou'ha2e'to'belie2e'that'*our'compan*'can'and'must'impro2e'to'meet'the' challenges'o#'tomorrow.'8urthermore-'*ou'need'to'belie2e'in'the'abilit*'o#'*our'people'to'recogni@e'opportunities'and' ma$e'impro2ements'in'an'ongoing'manner. I#'*ou'still'want'a'#anc*'de#inition'o#'Iai@en-'it'is'the' metaph*sics'o#'positi2e'change.'I#'*ou'pre#er-'it'is'a' philosoph*-'an'attitude-'a'wa*'o#'thin$ing-'and'a'wa*'o#' acting'all'in'one.'It'can'include'Iai@en'!ircles-'Cualit*' !ircles-'Total'Cualit*'"anagement-'/articipati2e' "anagement-'Ian':an-'BIT-'and'man*'other'use#ul'tools.' ;owe2er-'it'can'be'as'simple'as'*our'dedication'to'get' people'in2ol2ed'in'cutting'costs'through'positi2e'change.

How to Fail at 9ai7en X',o'around'telling'e2er*one'*ou'ha2e'a'great' program'to'sa2e'the'compan*'Y'Jright'now.K X':elie2e'that'*ou'$now'all'the'5uestions'and'ha2e' all'o#'the'answers'to'ma$e'!ontinuous' Impro2ement'wor$'in'*our'compan*. X':egin'be#ore'discussing'with'*our'$e*'people'to' decide'what'*ou'want'to'accomplish. X'.se'*our'own'personal'2ision'to'lead'the'e##ort' instead'o#'de2eloping'a'set'o#'long'range'goals'#or' *our'compan*. X':elie2e'in'changing'processes'and's*stems' alone'without'an*'attention'to'the'compan*' culture. X'7)pect'and'tolerate'no'#ailures'or'set-bac$s.

Pilot Progra(
9o'not'start'out'ma$ing'*our'!ontinuous'Impro2ement'/rogram'too'complicated.',o'slowl*.':e'willing'to'ta$e'a'step' or'two'bac$wards'#rom'time'to'time.'7)pect'mista$es.'9on<t'#rea$'out'when'the*'occur.'Learn'#rom'them.' I#'*ou'wish-'do'as'I'ha2e'done'and'begin'with'a'pilot'program'a#ter'*ou'ha2e'decided'on'a'2ision'o#'where'*our' compan*'needs'to'go.'Identi#*'a'critical'area'in'which'*ou'would'li$e'to'see'progress'made.'1elect'a'group'o#'capable' indi2iduals'to'ma$e'up'a'team.'"a*be'it'is'a'manu#acturing'department-'such'as'pac$ing.',et'the'super2isor'in'the' team'leadership'mode.'Let'them'begin'to'wor$'on'their'challenges.' ith'*our'leadership'#rom'the'top'and'their' initiati2es'#rom'the'bottom'*ou'will'ha2e'a'winning'e##ort. I'would'caution'*ou'not'to'let'an'atmosphere'o#'elitism'sur#ace.'I'ha2e'seen'this'turn'the'rest'o#'the'plant'against'the' idea. This'is'>ust'a'pilot'program'to'#ind'out'what'wor$s'and'what'doesnAt'in'*our'organi@ation.'It'can'also'ser2e'to'generate' interest'throughout'*our'organi@ation.'Loo$'at'it'as'a'primer.
Heprinted-'with'permission'#rom' ood'3' ood'/roducts-'cop*right'%005'-'NA+!7'/.:LI1;I+,-'ALL'HI,;T1'H717HN79'

quality circles and kaizen teams

Business studies students often come across the concept of quality circles, or "Kaizen". What does this mean and what are the practicalities of using Kaizen in a quality management system? We saw in our revision note on total quality management that a key principle of quality management is that of "continuous improvement".

Continuous improvement means just what it says. It is a philosophy that encourages all employees in an organization so that they perform their tasks a little better every day. It starts from the assumption that business processes e.g. production methods! purchasing! recruitment" can always be improved. #o why the use of the term Kaizen$ %aizen is a system for generating and implementing employee ideas popularized developed in &apan. 'he %aizen suggestion scheme helped many &apanese companies improve quality and productivity! which allowed them to offer better products at lower prices and therefore increase their market share. (uch of the success of %aizen came about because the system encouraged many small)scale suggestions that were cheap and quick to implement. 'hey also came from shop)floor employees ) who had a detailed appreciation of the benefit each change might make to the process concerned. *y implementing many small improvements! the overall effect was substantial. +ne of the most publicized aspects of the &apanese approach to quality management is the idea of ,uality Circles or %aizen teams. -rofessor &ohn +akland a leading authority on quality" defines a ,uality Circle.%aizen 'eam as a group of workers who do similar work and who meet/

) ) ) ) ) )

0oluntarily 1egularly In normal working time 2nder the leadership of their supervisor 'o identify! analyze and solve "work)related" problems 'o recommend solutions to management

3vidence of successful ,uality Circles suggests that there are no formal rules about how to organize them. 4owever! the following guidelines are often suggested/

) ) ) ) )

'he circle should not get too large ) otherwise it becomes difficult for some circle team members to contribute effectively (eetings should be help away from the work area ) so that team members are free from distraction 'he length and frequency of quality circle meetings will vary ) but when a new circle is formed! it is advised to meet for about one hour! once per week. 'hereafter! the nature of the quality problems to be solved should determine how often the circle needs to meet ,uality circles should make sure that each meeting has a clear agenda and objective 'he circle should not be afraid to call on outside or e5pert help if needed

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'http://www.gembutsu.com/articles/leanmanu#acturingglossar*.html''9/03/09 :,:'51'is'a'house$eeping'methodolog*'#or'the'shop'#loor.'There'are'#i2e'rules'o#'house$eeping'#or'a'lean'en2ironment'and'the*'help'to' e)pose'waste'and'support'the'discipline'needed'to'implement'the'To*ota'/roduction'1*stem.' The'#i2e'1<s'are'described'below:' 1$ ,eiri )/rgani7ation*:'Ieep'>ust'what'is'needed-'clearl*'distinguish'between'what'is'needed'and'$ept'and'what'is'unneeded'and'thrown' awa*.

2$ ,eiton )/rderliness*:';a2e'a'place'#or'e2er*thing'and'implement'a's*stem'whereb*'e2er*thing'is'in'its'place.'Frgani@e'in'a'wa*'that' ensures'that'necessar*'things'are'$ept'close'at'hand.'Tools'and'other'ob>ects'should'be'easier'to'#ind'and'returned'to'their'proper'location. 4$ ,eiso )#leanliness*:'This'can'be'2iewed'as's*stematic'clearing'where'e2er*thing'is'cleaned-'inspected'and'maintained'on'a'regular' basis. G$ ,eiketsu ),tandardi7ation*:'7stablish'methods'within'the'compan*'that'will'ensure'the'e##ecti2e'continuation'o#'steps'?'thought'3. :$ ,hitsuke )2isci'line*:'1et'us's*stems'that'sustain'the'#i2e'1'process.'7nsure'that'all'E'steps'are'maintained. I#'a'compan*'does'not'ha2e'the'discipline'to'e)ecute'the'#i2e'1<s-'it'will'not'ha2e'the'discipline'to'complete'standard'wor$-'pull's*stems-'and' other'lean'techni5ues.'51'is'the'2er*'#irst'step'on'a'compan*<s'learn'>ourne*. H A H' Andon: 1impl*'means'JlightK'in'Bapanese.';owe2er-'in'a'T/1'en2ironment-'an'andon'is'an*'2isual'indicator'signaling'that'a'team'member' has'encountered'an'abnormal'situation'which'can'not'be'resol2ed'without'pre2enting'a'stoppage'4as'de#ined'b*'ta$t'time6.'/oor'5ualit*-'lac$' o#'a'parts-'paperwor$-'in#ormation'or'tools'ma*'cause'an'abnormal'condition.'The'$e*'to'e##ecti2e'andons'is'that'the*'be'2isual'and'support' Jmanagement'b*'sightK. Andon Board:'A'2isual'control'de2ice'in'a'wor$'area-'t*picall*'a'lighted'o2erhead'displa*'gi2ing'the'current'status'4green-'*ellow-'red6'o#' each'step'in'the'production's*stem'and'alerting'team'leaders'and'super2isors'to'e)isting'or'emerging'production'problems. Auto(ation: 7mplo*ing'machines'to'do'the'wor$'o#'people.'The'steam'engine'and'the'automation'that'it'enabled'was'the'bac$bone'o#'the' Industrial'He2olution. Autono(ation )&ikoka*:'Trans#erring'human'intelligence'to'automated'or'semi-automated'machiner*'so'that'machines'and'not'people'are' able'to'detect'production'de#ects'and'immediatel*'stop'themsel2es.'.suall*-'such'a'stop'is'signaled'2ia'an' 'signal.'This'notion'o#' built-in-5ualit*'was'pioneered'b*'1a$ichi'To*oda'when'he'in2ented'automatic'te)tile'looms'that'stopped'the'instant'a'thread'was'bro$en.'In' Bapanese-'this'concept'is'called'.idoka'and'it'is'a'critical'element'o#'the'T/1';ouse. Auto(atic !i(e: The'time'when'a'machine'is'running'on'an'automatic'c*cle'and'a'person'is'not'needed'to'operate'the'e5uipment.'' Automatic'Time'is'also'called'"achine'Time'and'it'is'one'o#'three'measures'on'a'1tandard' or$'!ombination'1heet. +::'I#'an'operator'is're5uired'to'watch'a'machine'wor$-'this'is'to'be'considered'not'automatic'time-'but'operator'time.'
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andon

HBH Batch Production: In'contrast'to'one-piece-#low'4or'#low6-'batch'production'is'a'mass-production'practice'de2eloped'b*';enr*'8ord.'It'is'the' practice'o#'ma$ing'large'lots'o#'a'particular'item'to'gain'economic'e##iciencies'o#'e5uipment'and'machine'changeo2er'time.'T/1'teaches'that' such'a'practice'is'ine##icient'in'the'long-term'because'it'results'in'o2erproducing'unwanted'product.'

See the se'en wastes.

Breakthrough .('rove(ent )9aikaku*: A'ma>or-'signi#icant'impro2ement'that'occurs'a#ter'man*'small-'incremental'impro2ements'4$ai@en6.' Iai$a$u'should'come'naturall*'a#ter'completing'man*'4sometimes'hundreds6'$ai@ens='it'is'not'something'that'is'#orced.

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H#H #haku<#haku: A'Bapanese'word'meaning'load-load-'it're#ers'to'a'single-piece'#low'cell'where'the'onl*'thing'that'an'operator'does'is'load' each'machine'in'se5uence.'The'operator'onl*'loads'material'because'all'other'operations'ha2e'been'automated'and'do'not're5uire'human' super2ision.'This'is'an'ad2anced'lean'techni5ue'and'ma*'ta$es'*ears'o#'hard'wor$'to'de2elop'in'a'single'cell.';owe2er-'the'bene#its'are' signi#icant'4elimination'o#' I/-'de#ect'#ree'production'and'2er*'high'utili@ation'o#'labor'and'space6. #hangeover !i(e: The'time're5uired'#or'a'machine'to'produce'a'di##erent'part'4#or'e)ample-'a'new'stamping-'a'new'color'in'a'paint's*stem-' a'new'mold'in'an'in>ection'molding'machine-'etc...6.'!hangeo2er'time'is'measured'#rom'the'last'good'part'o#'the'pre2ious'process'to'the'#irst' good'part'o#'the'subse5uent'process.''Heducing'changeo2er'time'is'a'$e*'component'o#'implementing'a'pull'production's*stem'which' operates'with'as'little'in2entor*'as'possible.'

#ontinuous Flow: 8low'o#'products'in'a'manner'through'the'production'operation.'The'ideal'situation'is'one-piece'#low'at'and'between'the' processes.'The'intent'o#'#low'production'is'to'increase'the'2elocit*'o#'products'and'ma$e'the'production'c*cle'predictable. #oncrete Head: A'Bapanese'term'#or'someone'who'resists'and'will'not'accept'change.''!oncrete'heads'do'not'accept'that'businesses'must' be'#ocused'on'waste'elimination'and'customer'satis#action'and'other'concpets'inherent'to'a'lean'production's*stem.'' #ycle !i(e: !*cle'time'is'measured-'usuall*'with'a'stop'watch.'The'actual'time'it'ta$es'to'complete'a'process'#rom'start'to'#inish'to'produce' one'unit'4one'c*cle'o#'an'operation6.'An'emplo*ee<s'c*cle'time-'must'meet' '4with'an'appropriate'bu##er'o#'sa#et*'time6.'I#'c*cle' time'is'higher'than'ta$t'time-'the'customer<s'needs'will'not'be'met.'I#'it'is'lower-'there'will'be'o2erproduction'/'e)cess'in2entor*'or'operator' idle'time-'each'o#'which'is'a'waste'and'costs'mone*.'Ieeping'c*cle'time'e5ual'to'ta$t'time'will'pre2ent'waste'#rom'creeping'bac$'in'the' process.' Fnl*'when'c*cle'time'#or'e2er*'operation'in'a'complete'process'is'reduced'to'e5ual'ta$t'time'can'products'be'made'in'a'single-piece'#low' process.
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ta$t'time

H?H ?li(ination of "aste:'A'philosoph*'which'states'that'all'acti2ities'underta$en'need'to'be'e2aluated'to'determine'i#'the*'are'necessar*'or' unnecessar*'as'de#ined'b*'the'customer.'The'philosoph*'o#'waste'elimination'is'the'bac$bone'o#'the'To*ota'/roduction'1*stem. ?('loyee .nvolve(ent: A'crucial'aspect'o#'!ontinuous'Impro2ement'based'on'two'#acts:' 8act'?:'Those'who'do'the'>ob'e2er*'da*'ha2e'2ital'in#ormation'#or'eliminating'waste'and'adding'2alue'and'sol2ing'real'problems.' 8act'%:'To'get'commitment'#rom'those'who'will'implement'the'plans'de2eloped-'the*'need'to'be'in2ol2ed'in'the'decision'ma$ing'process. ?rror Proofing: 1ee'/o$a-Oo$e'4"ista$e'/roo#ing6.
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H F H' Five "hy5s: "ethod'o#'e2aluating'a'problem'or'5uestion'b*'as$ing'Jwh*K'#i2e'times.'The'purpose'is'to'get'to'the'root'cause'o#'the'problems' instead'o#'addressing'the's*mptoms.':*'as$ing'and'answering'wh*'#i2e'4or'more6'times-'the'root'cause'becomes'e2ident'and'the'proper' correcti2e'action'can'be'ta$en. Flow Production: 1ame'as'single-piece-#low'or'one-piece-#low.'9escribes'how'goods-'ser2ices'and'in#ormation'are'processed.'That'is-' once'piece'at'a'time.'This'can'be'a'part-'a'document-'in2oice'or'customer'order.'It're>ects'the'concept'o#'batch-'large'lot'or'mass'processing.' 8low'2erticall*'integrates'all'operations'and'#unctions'as'operationall*'or'se5uentiall*'per#ormed.'It'also'encompasses'pull'or'demand' processing.',oods'are'not'pushed'through'the'process-'but'pulled'or'demanded'b*'succeeding'operations'#rom'preceding'operations.
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H @ H' @e(%aI: JActual'placeK'or'the'place'where'real'action'occurs-'that'is'where'products'or'ser2ices'are'per#ormed.'In'a'manu#acturing' en2ironment-'the'gemba'o#ten're#ers'to'the'shop'#loor-'because'it'is'there'that'product'is'being'trans#ormed. @e(%utsuI: In'Bapanese-'it're#ers'the'actual'product.'These'are'a'companies'parts-'tools-'>igs-'#i)tures-'machines-'e5uipment'and'materials' all'used'to'manu#acture'5ualit*'products. @enjitsuI: In'Bapanese-'it're#ers'to'the'Jactual'#actsK'or'reliable'and'obser2ed'data're5uired'to'understand'what'the'actual'situation/problem' is. I!hree @en Princi'le: hen'sol2ing'a'problem-'the'combination'o#'going'to'the'gemba-'to'obser2e'the',embutsu'in'order'to'obtain'gen>itsu.' ith'these'three'Jgen<sK'a'problem'can'be'properl*'sol2ed.
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H H H' Hanedashi:'A'de2ice'or'means'#or'automatic'unloading'o#'a'wor$'piece'#rom'one'operation'or'process.'This'same'de2ice'will'pro2ide'proper' orientation'o#'the'ne)t'wor$'piece'#or'the'ne)t'operation'or'process.'!rucial'#or'a'J!ha$u-!ha$uK'line. Hoshin 9anri:'A'strategic'decision-ma$ing'tool'#or'a'#irm<s'e)ecuti2e'team'that'#ocuses'on'resources'on'the'critical'initiati2es'necessar*'to' accomplish'the'business'ob>ecti2es'o#'the'#irm.':*'using'2isual'matri)'diagrams'similar'to'those'emplo*ed'#or'5ualit*'#unction'deplo*ment-' three'to'si)'$e*'ob>ecti2es'are'selected'while'all'others'are'clearl*'deselected.'The'selected'ob>ecti2es'are'translated'into'speci#ic'strategies' and'deplo*ed'down'to'the'implementation'le2el'in'the'#irm.';oshin'Ianri'uni#ies'and'aligns'resources'and'established'clearl*'measurable' targets'against'which'progress'toward'the'$e*'ob>ecti2es'is'measured'on'a'regular'basis.

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H & H' &ust .n !i(e )&.!*:'A'strateg*'that'e)poses'waste-'ma$es'continuous'impro2ement'a'realit*-'and'relies'on'total'emplo*ee'in2ol2ement.'It' concentrates'on'deli2ering'what'the'customer'wants-'when'the*'want'it-'in'the'5uantit*'the*'want.'The'$e*'elements'o#'BIT'are'#low-'pull-' standard'wor$'4with'standard'in-process'in2entories6-'and'ta$t'time.

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H 9 H' 9ai7en )#ontinuous .('rove(ent*:'An'organi@ational'attitude-'approach'and'philosoph*'to'doing'business.'It'is'the'$e*'thrust'to' maintaining'or'achie2ing'competiti2e'ad2antage'through'a'well'managed-'d*namic'change'process.'It'is'customer'#ocused-'e2er'changing-' and'ma)imi@ed'when'all'associates'use'$ai@en'to'achie2e'the'primar*'5ualit*-'cost'-'deli2er*-'sa#et*-'and'morale'goals.'The'$e*'to'$ai@en'is' to'use'it'as'a'tool'to'accomplish'the'polic*'deplo*ment'brea$through'ob>ecti2es. 9an%an )sign%oard*:'9esignates'a'pull'production'means'o#'communicating'need'#or'product'or'ser2ice.'Friginall*'de2eloped'as'a'means' to'communicate'between'operations'in'di##erent'locations-'it'was'intended'to'communicate'a'change'in'demand'or'suppl*.'In'application-'it'is' generall*'used'to'trigger'the'mo2ement'o#'material'to'or'though'a'process.
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H L H' Level ,cheduling )Heijunka*:'The'creation'o#'a'le2el'schedule'b*'se5uencing'orders'in'a'repetiti2e'pattern'and'smoothing'the'da*'to'da*' 2ariations'in'total'orders'to'correspond'to'longer-term'demand.'In'other'words-'crating'a'production'schedule'based'on'a'constant'2olume' needed'within'a'gi2en'time'and'2ariet*'o#'product'called'Jmi)ed'lotK'production.'The'goal'is'to'a2erage'both'the'2olume'and'the'mi)'o#' products.

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H'

ake .t Kgly: Iai@en'and'T/1'does'not'#i)'e2er*thing'right'now.'Instead-'it'e)poses'problems'that'need'to'be'#i)ed.'Instead'o#'co2ering'up' the'problems-'ma$e'it'Jugl*K'as'possible'so'it'gets'attention.' hat'gets'our'attention'gets'resol2ed.'This'is'a'2er*'di##icult'concept'#or' estern' managers'to'embrace. ilk 0un:'A'routing'o#'a'suppl*'or'deli2er*'2ehicle'to'ma$e'multiple'pic$ups'or'drop-o##s'at'di##erent'locations'on'a'regularl*'scheduled'basis. istake Proofing )Poke<Aoke*: 9e2eloping'a's*stem'so'that'it'is'impossible'to'ma$e'a'mista$e'or'produce'a'de#ect. onu(ent: An*'design-'scheduling-'or'production'technolog*'with'scale're5uirements'necessitating'that'designs-'order'and'products'be' brought'to'a'machine'to'wait'in'a'5ueue'#or'processing.'!ontrast'with'right-si@ed'tool.'A'piece'o#'e5uipment'4usuall*'large'and'e)pensi2e6' that'cannot'easil*/ine)pensi2el*'be'mo2ed-'e2en'i#'it'would'be'good'to'so'do'in'terms'o#'T/1'principles.'Also-'continuous'impro2ement' re5uires'continuous're-arrangement='there#ore'monuments'are'waste. uda and the F wastes: aste.'An*'acti2it*'that'consumes'resources'but'creates'no'2alue. 1e2en't*pes'o#'waste'ha2e'been'identi#ied'#or'the'shop'#loor.'The*'are'waste'#rom'4?6'o2er'production-'4%6'waiting'or'idle'time-'436' transportation-'4E6'ine##icienc*'o#'the'process'itsel#-'456'in2entor*-'466'unnecessar*'motion'and'e##ort'and'4G6'de#ects. ura: F2erloading'an'area'or'as$ing'#or'otherwise'unreasonable'wor$.

uri: .ne2en'#low'o#'parts.
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H L H' Lichijo 9anri: 9ail*'#undamental'management.'This'is'the'opposite'o#';oshin'Ianii'or'/olic*'9eplo*ment-'which'is'the'direction'setting' management'or'strategic'planning'#unction.

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H P H' Pull ,yste(: A'production'method'in'which'the'production'o#'an'item'starts'onl*'when'there'is'actual'demand'#rom'a'customer'4as'opposed' to'anticipated'#rom'a'#orecast6.'The'demand'o#'that'customer'starts'4pulls6'the'ne)t'downstream'operation'into'the'production'process-'etc.' The'opposite'o#'pull'production'is'push'production. Push Production: The't*pical'method'o#'JpushingK'large'lots'o#'material'through'the's*stem-'usuall*'managed'b*'a'complicated'4o#ten' computeri@ed6'process'to'trac$'where'items'are'and'how'to'connect'these'items'into'a'customer'satis#action'unit.'Ine2itabilit*'this'leads'to' other'waste#ul'processes-'such'as'e)pediting.'The'production'o#'items'based'on'a'predetermined'schedule'or'#orecast.'The'result'is' in2entor*'V'manu#actured'items'#or'which'there'is'not'*et'a'customer.'A'push's*stem'is'the'e)act'opposite'o#'a'pull's*stem.
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H > H' >,#,,,2, : These'are'the'basic'dri2ers'o#'e2er*'business'and'are'Cualit*-'!ost-'9eli2er*-'1a#et*'and'"orale.

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H 0 H' 0ight ,i7ed !ool: A'design-'scheduling-'or'production'de2ice/tool'that'can'be'#itted'directl*'into'the'#low'o#'products'within'a'product'#amil*' so'that'production'no'longer're5uires'unnecessar*'transport'and'waiting.'!ontrast'with'monument.

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H , H' ,'aghetti #hart:'A'map'4#loor'plan6'o#'the'path'ta$en'b*'a'speci#ic'product/part/material/person'as'it'or'the*'tra2el'through'the'2alue'stream' in'a'mass-production'organi@ation-'so-called'because'the'product<s'route't*picall*'loo$s'as'disorgani@ed'as'a'plate'o#'spaghetti.' ,tandard "ork: 1tandard'wor$'lists'the'normal'tas$s'done'with'the'least'amount'o#'waste'possible'at'the'current'time'4o#'course-'it'will' continuall*'be'impro2ed.6'1tandard'wor$'includes'the'amount'o#'time'needed'#or'each'tas$.'1tandard'wor$'#ocuses'on'the'emplo*ee-'not'the' e5uipment'or'the'materials.'1tandard'wor$'is'completed'b*'the'actual'operator'per#orming'the'tas$'since'the*'$now'best'the'details'o#'the' process.'1tandard'wor$'is'o#ten'con#used'with'wor$'standards'and/or'wor$'instructions.'The*'are'not'the'same'thing.'1tandard'wor$'reduces' 2ariation'an'increases'consistenc*'that'is'necessar*'#or'#irst-time'5ualit*.' ,tandard "ork #o(%ination ,heet:'A'#orm'that'2isuall*'charts'the'in#ormation'#rom'a'time'sheet'obser2ation'#orm'in'terms'o#'an' emplo*ees'acti2it*-'machine'time'and'mo2ing'time.'It'separates'time'between:'man-'machine'and'mo2ement'4wal$ing6.' ,tandard "ork ,heet:'A'#orm'to'2isuall*'describe'the'standard'operation-'including'inspection'steps-'sa#et*'issues-'and'standard'wor$'in' process.'It'is'a'la*out'o#'the'cell'area'with'all'the'mo2ement/steps'in'process'noted'li$e'a'

spaghetti'diagram.
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H ! H' !akt !i(e:'Ta$t'time'is'a'calculated'2alue.'The'#ormula'#or'ta$t'time'is'ANAILA:L7'/HF9.!TIF+'TI"7'/'!.1TF"7H'97"A+9.'1ince' ta$t'time'is'de#ined'b*'the'customer'4denominator6-'it'becomes'a'2er*'important'number'in'a'lean'en2ironment'and'dri2es'all'shop'#loor' decisions.

!hrough'ut !i(e: The'time're5uired'#or'a'product'to'go'thought'a'process.'.suall*-'throughput'time'is'measured'#rom'the'receipt'o#'raw' material'until'that'raw'material'is'shipped'to'the'customer.'1ome'companies'begin'the'process'with'the'receipt'o#'a'customer<s'order. !otal Productive aintenance )!P *:'/re2entati2e'maintenance'carried'out'b*'all'emplo*ees.'It'is'e5uipment'maintenance'per#ormed'on'a' compan*'wide'basis.'T/1'has'#i2e'goals:' ?. %. 3. E. 5. "a)imi@e'e5uipment'e##ecti2eness.' 9e2elop'a's*stem'o#'producti2e'maintenance'#or'the'li#e'o#'the'e5uipment-' In2ol2e'all'departments'that'plan-'design-'use-'or'maintain'e5uipment'in'implementing'T/".' Acti2el*'in2ol2e'all'emplo*ees.' /romote'T/"'through'moti2ational'management.
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H 8 H' 8alue ,tea( a''ing:'Identi#ication'o#'all'the'speci#ic'acti2ities'occurring'along'a'2alue'stream'#or'a'product'or'product'#amil*.'This'is'part' o#'creating'a'lean'enterprise.'The'output'should'be'a'list'o#'action'items'to'be'done'to'impro2e'the'process.

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H ", M, A and 1 H' "aterstrider ) i7usu(ashi*: ater-beetle'or' ater-spider.'A'term'used'to'describe'the'acti2ities'o#'the'person'responsible'#or'maintaining' correct'in2entories'on'the'production'line.