The 8 disciplines are: Establish a small group of people with the knowledge, time, authority and skill to solve the problem and implement corrective actions. The group must select a team leader. Describe the problem in measurable terms.
Muda of Correction Muda of Over Production Just-In-Time production is an ironclad rule at Toyota and producing anything 1 earlier than needed or 2 in greater volumes than needed as indicated by kanban or other indicators results in excess inventory and is known as muda or over production.
This muda often hides muda of waiting and muda of motion.
It also leads to muda by an increase in the number of conveyance vehicles and pallets. Among the different kinds of muda, muda of over-production is the most serious. Muda of Waiting This refers to a situation where a worker who has been working according to a standardized work sequence finds himself unable to process to the next job.
This often occurs due to the volume of work being low. Muda in Processing Any work or processing that does not add value to the product and advance the production process or contribute to the precision or quality of the processed units is referred to as Muda in Processing.
Muda in Inventory All of the inventory materials in-process work and finished products that derives from the process of production and conveyance. Muda of Motion Muda of Motion is any human movement in production that adds no value to the product.
Muda of Correction This refers to the muda of producing defective items which must be repaired or discarded. Includes the regular processes which tend to make people less aware of the muda involved and therefore impair improvement. Mura Unevenness The irregularities that sometimes happen in the production schedule or in the volume of parts or vehicles produced.
Instead of remaining at set levels, volume moves temporarily up or down. For workers, it refers to workloads which vary from the standard. Muri Overburden At the jobsite, this means giving too heavy a mental or physical burden to workers on the shop floor.
For machinery, muri means trying to have equipment do more than its capability. Multi-Process Handling In Multi-Process Handling, one shop worker will move down a row of machines or equipment arranged in the order of the flow of production processes and will perform all necessary jobs within the Takt-Time.
Multi-Machine Handling Multi-Machine Handling means that one shop worker will move along a group of machines or pieces of equipment and operate them to perform multiple jobs by himself.
Those machines and equipment are grouped together because of the similarity of processes involved or similarity of the machines used. Multi-Skill Development In order to conduct one-piece-at-a-time production and multi-process handling, a shop worker must be able to perform many different jobs, operating diverse types of machinery and equipment.
Such a shop worker is multi-functional worker. This flexibility would not be possible without multi-function workers. One-Piece-At-a-Time Production This refers to the system of production in which only one part or one vehicle at a time is processed or assembled and sent along the production line to following processes.
On-Line Set-Up Of the many operations involved in set-up jobs, this refers to those operations which cannot be carried out without stopping the line or machines. Such operations include the actual changing of dies, cutting tools, jigs, etc.
Off-Line Set Up Those parts of the set-up operation which can be done without stopping the line or machinery. For example, the work of preparing and putting away dies, cutting tools and jigs.
Operational Availability The time that a machine operates maintenance free as a percentage of the time during which it is switched on.
This is equivalent to the reliability of equipment and its maintenance.Toyota’s lean production system has transformed the manufacturing industry.
David Landes, an economic historian from Harvard describes it as the most important technical innovation since Ford’s successful implementation of the moving assembly line.
Lean Manufacturing is not especially new. It derives from the Toyota Production System or Just In Time Production, Henry Ford and other predecessors.. The lineage of Lean manufacturing and Just In Time (JIT) Production goes back to Eli Whitney and the concept of interchangeable parts.
May 14, · Lean is a production method designed by Toyota (known as the Toyota Production System, or TPS) to reduce cost and improve profits. It does this by reducing waste, inventory, keeping headcount as low as possible, and producing only what is needed when it .
Key Lean Manufacturing Principles. There are several key lean manufacturing principles that need to be understood in order to implement lean.
Failure to understand and apply these principles will most likely result in failure or a lack of committment from everyone in your organization. The production system developed by Toyota Motor Corporation to provide best quality, lowest cost, and shortest lead time through the elimination of waste.
TPS is comprised of two pillars, just-in-time and jidoka, and often is illustrated with the “house” shown at right. Feb 16, · Elon Musk is convinced Tesla can out-Toyota Toyota on lean manufacturing. But while he's pushing for more automation, Toyota is heading in the opposite direction.