Category Archives: Uncategorized

Ten Types of Human Mistakes

Forgetfulness Misunderstanding Wrong identification Lack of experience Willful (ignoring rules or procedure) Inadvertent or sloppiness Slowliness Lack of standardization Surprise (unexpected machine operation, etc.) Intentional (sabotage)

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The Seven Guidelines to Poka- Yoke Attainment

1.)  Quality Processes – Design “Robust” quality processes to achieve zero defects. 2.)  Utilize a Team Environment- leverage the teams knowledge, experience to        enhance the improvement efforts. 3.)  Elimination of Errors -Utilize a robust problem solving methodology to drive defects towards zero. 4.)  Eliminate the “Root Cause” of The Errors-Use the 5 Why’s and 2 […]

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QCD 101 | For Assembly

Visualization Q: Create a situation where 4M changes, quality problems (in the line) of the day, past quality problems (in-coming and in-line quality), are easily observed. C: Cost & profit should be visible on a daily basis by controlling the profit by lines. D: By using inventory control plans, the inventory plans and the results […]

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QCD 101 | For the Shipping Area

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Visualization Clearly Identify: what, how many pcs, where to, what time and which track. Clearly Identify: from which line or store, when, and how many pcs are pulled-in. Clearly Identify: shipping preparation hourly status. Visual Control Confirm the hourly status per the plan, and if any abnormality (delay) was observed, identify the cause and clearly […]

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QCD 101 | Finished Goods Store

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Visualization Locations should be designated by products and production lines. Inventory situation including inventory plans should be clearly visible. Visual Control Check the inventory to see if the amount meets the inventory plan. If abnormality was observed, identify the cause and describe the counter measures on a control board. Supervisors should confirm the content on […]

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Study Guide – Toyota Way Fieldbook – VSM

Starting the Journey of Waste Reduction Part 3 Chapter 3 – VALUE STREAM MAPPING APPROACH By Swati Jadhav Recently I had a chance to read the book called The Toyota Way Fieldbook, by J. Liker and it changed my viewpoint towards Lean methodology. I used the guidelines provided by the book for the Value stream […]

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What is your “Why”? Tell Your Story!

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The Goals of the Lean Enterprise Your organization can apply lean methods and techniques to your product-production and business processes to deliver better value to your customers. A lean initiative has four man goals: Goal #1: Improve quality. Quality is the ability of your products or services to conform to your customers’ wants and needs […]

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5S System – FREE Templates – 001

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A system designed to organize and standardize a workplace and consisting of five component parts: Sort, Set in Order, Shine, Standardize, and Sustain. So powerful but rarely implemented to the extent possible required to actually see gains in cultural change. Simple yet effective methods work best. GET YOUR FREE – 5S Schedule and Check-Sheet Templates […]

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Set in Order (for 5S)

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Set in Order (for 5S): Step 2 of the 5S System. To identify the best location for remaining items, relocate out of place items, set inventory limits, and install temporary location indicators – Institute of Operational Excellence

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Processing Waste

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Processing Waste: Effort that adds no value to the product or service from the customers’ viewpoint. – Institute of Operational Excellence

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