HshsThe vast quantity of Lean Manufacturing tools, methods and principles, makes it difficult to keep track of everything. To ease your life a little, here a list of 44 main Lean tools and principles.
5 whys
Why? Why? Why? Why? Why?
5 whys is an iterative interrogative technique used to explore the cause-and-effect relationships underlying a particular problem. The primary goal of the technique is to determine the root cause of a defect or problem by repeating the question “Why?”. Each answer forms the basis of the next question.
5M
Man, Machine, Material, Method, Medium
5M represent the 5 main influence factors for a certain outcome. These factors are: Man, Machine, Material, Method, Medium. In some cases 2M’s can be added for Management and Measurement.
5S
Sort, Set in Order, Shine, Standardize, Sustain
5S describes how to organize a work space for efficiency and effectiveness. The method describes how to sort, organize, clean, standardize and continuously improve the organization of all needed items at a workplace.
5W2H
What? Why? Where? When? Who? How? How much?
5W2H summarizes an empirical method of questioning. This systematic questioning makes it possible to collect all the necessary information to report a certain situation.
6 Sigma
6σ
Six Sigma (6σ) is a set of techniques and tools for process improvement. Six Sigma uses empirical and statistical methods seeking to improve the quality of the output of a process by identifying and removing the causes of defects, minimizing variability.
8D
8 Disciplines
8D is a method developed at Ford Motor Company used to approach and to resolve problems. It’s purpose is to identify, correct, and eliminate recurring problems. It establishes a permanent corrective action based on statistical analysis of the problem and on the origin of the problem by determining the root causes.
A3
A3 Problem Solving
A3 problem solving is a structured problem-solving and continuous-improvement approach. It provides a simple and strict procedure that guides problem solving by workers. The approach typically uses a single sheet of A3-size paper, which is the source of its name.
Andon
Paper Lantern
Andon is system to notify a support team about a process problem. The alert can be activated manually by a worker using a pull cord or button. It can also be activated automatically by the production equipment itself. The system may include a means to stop production so the issue can be corrected.
APQP
Advanced Product Quality Planning
APQP is a framework of procedures and techniques used to develop products, it serves as a guide in the development process. APQP specifies three phases: Development, Industrialization and Product Launch.
Chaku-Chaku
Load-Load
Chaku Chaku is a way to operate a semi-automated manufacturing line. One (or more) workers walk around the line, add parts to the processes, and then start the process. While the process works on the part automatically, the worker adds the next part to the next process, and so on.
CIP
Continuous Improvement Process
CIP is an ongoing effort to improve products, services, or processes. These efforts can seek “incremental” improvement over time or “breakthrough” improvement all at once.
DFSS
Design for Six Sigma
DFSS is a management method related to Six Sigma. It is based on the use of statistical tools and has the objective to define and implement the needs of customers and business into a new created product.
DMAIC
Design, Measure, Analyze, Improve, Control
DMAIC refers to a data-driven improvement cycle used for improving, optimizing and stabilizing business processes and designs. The DMAIC improvement cycle is the core tool used to drive Six Sigma projects.
FMEA
Failure Mode and Effect Analysis
FMEA is the process of reviewing products to identify potential failure modes. The cause and effects of failures are analyzed according to their Probability, Detection and Severity resulting in a RPN (risk priority number). Preventive measures are then implemented according to the RPN value.
Gemba
Scene of Action / Shop Floor
Gemba is the factory floor, the place where value is created. The idea of gemba is that the problems are visible at the shop floor and the best improvement ideas will come from going there. The gemba walk, is an activity that takes management to the front lines to look for waste and opportunities for improvement.
Heijunka
Production Leveling
Heijunka is a technique for leveling the production quantities over time. The goal is to produce goods at a constant rate so that processing is carried out at a constant and predictable rate.
Hoshin Kanri
Policy Management
Hoshin Kanri is a 7-step process used in strategic planning in which strategic goals are communicated throughout the company, broken down and then put into action.
Ishikawa
Fishbone Diagram
Ishikawa diagram are causal diagrams that show the causes of a specific event. Common uses of the Ishikawa diagrams are during a problem solving process to identify potential factors causing an overall defect.
Jidoka
Autonomation
Jidoka represents the implementation of supervisory functions to detect abnormal situations. It is a quality control process based on four principles: Detect the abnormality, Stop the process, fix the immediate condition, investigate the root cause and install countermeasures.
JIT
Just-in-Time
JIT is a methodology aimed primarily at reducing times within the production system as well as response times from suppliers and to customers. It focus lays on the supply of the needed material at just the right time, right quantity and quality.
Kaikaku
Radical Change
Kaikaku is concerned with making fundamental and radical changes to a production system, unlike Kaizen which is focused on incremental changes. Kaikaku means that an entire business is changed radically, typically in the form of a project.
Kamishibai
Paper Play
Kamishibai boards are used as a visual control for performing audits within a manufacturing process. A series of cards are placed on a board and selected at random or according to schedule by supervisors and managers of the area. This ensures that periodic process confirmations are being done.
Kanban
Signboard
Kanban is a material supply system based on consumption. The system takes its name from the cards that track production, steering the replenishment of goods within a factory.
Kata
Form, Pattern
Improvement Kata and Coaching Kata are means for making the Continual improvements. Kata is the method through which an organization can develop solutions along an unpredictable path. It is a routine for moving from the current situation to a new situation in a creative, directed, meaningful way.
KPI
Key Performance Indicator
KPI is a type of performance measurement which evaluates the success of an organization or of a particular activity
LSW
Leader Standard Work
LSW is the repetitive pattern of activities that represent the current less wasteful method of planning and controlling normal business process. It contains a list of daily tasks performed to sustain the lean management system.
Makigami
Role of Paper
Makigami is a systemic process mapping and improvement method. It focuses on visualizing aspects of the organization which are not physical or directly visible. The Makigami Process Map also can be used to improve the investigated process by designing a future state map after taking away the identified losses.
Milk Run
Milk Run
A Milk Run is a delivery method used to transport mixed loads from various suppliers to one customer. Instead of each supplier sending one truck every week, one single truck visits all the suppliers to pick up the loads for that single customer.
MMA
Multi Moment Analysis
MMA or Sampling Work is a special statistical technique that enables you to gain data and information about your work procedures. It is MMA’s main objective to provide data and facts about the effort distribution in your enterprise.
MSA
Measurement Systems Analysis
MSA is a thorough assessment of a measurement process and typically includes a specially designed experiment that seeks to identify the components of variation in that measurement process.
MTM
Methods Time Measurement
MTM is a motion time system that is used to analyze the execution of any manual task. As result of that analysis, the standard times for execution of these tasks are defined.
Muda
Waste (non-value adding)
Muda means waste through non value adding activities. From an end-customer’s point of view, value adding work is any activity that produces goods or provides a service for which a customer is willing to pay. Muda is everything else which is done but the customer is not willing to pay. Waste reduction is an effective way to increase profitability. 7 Lean Wastes are: Transport, Inventory, Movement, Waiting, Over-processing, Over-production, Defects
Mura
Waste (unevenness or inconsistency)
Mura is the waste of unevenness or inconsistency. By failing to level the production volumes/demands, inventories, waiting times and many other wastes might be created
Muri
Waste (overburden)
Muri is a kind of waste caused by overburden, creating unnecessary stress to employees or processes. It can be caused by factors like lack of training, unclear working standards, wrong tools and many others.
PDCA
Plan, Do, Check, Act
PDCA is an iterative four-step management method used for the control and continuous improvement of processes. It is also known as the Deming wheel.
Poka-Yoke
Mistake proofing
A poka-yoke is any mechanism that helps an operator avoid mistakes. Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors.
SFM
Shop Floor Management
SFM is a method to solve problems and improve performance at the gemba. Through short meetings at the shop floor, the status and hot topics are addressed, information shared and solutions speeded up.
SMED
Single Minute Exchange of Die
SMED provides a rapid and efficient way of converting a manufacturing process from running the current product to running the next product. This rapid changeover is key to reducing production lot sizes and improving flow.
SPC
Statistical Process Control
SPS is a method of quality control which employs statistical methods to monitor and control a process. This helps to ensure that the process operates efficiently, producing more specification-conforming products with less waste (rework or scrap).
SWOT
Strength, Weakness, Opportunities, Threats
SWOT is a strategic planning technique used to identify strengths, weaknesses, opportunities, and threats related to business or projects. It is designed for use in the preliminary stages of decision-making processes or as a tool for evaluation of the strategic position of an organization.
Takt-Time
Takt Time
Takt time is the average time between the start of production of one unit and the start of production of the next unit. The takt time should be based on customer demand. It is obtained by dividing the net available working time by the customer demand.
TPM
Total Productive Maintenance
TPM focuses on keeping all equipment in top working condition to avoid breakdowns and delays in manufacturing processes.
TWI
Training Within Industry
TWI was created in the United States during world war 2. It consists of an improved method for job training which addressed the shortfall of trained and skilled personnel at the time.
VSM/VSD
Value Stream Map/Design
A value stream map is a visual tool that displays all critical steps in a specific process and quantifies the time and volume at each stage. Value stream maps show the flow of both materials and information as the products progress through the process.
Did I forgot anything? If yes, please leave a comment. I am happy to hear from you. 🙂
