Balanced Plant - A plant where capacities of all resources are balanced exactly with market demand.
Batch Production - A "Push" system of production where resources are provided to the consumer based on forecasts or schedules.
Cellular Manufacturing/Cells - Linking of manual and machine operations into the most efficient combination to maximize value added content while minimizing waste of motion and valuable resources.
Continuous Improvement Process (CIP) - The never-ending process of eliminating waste within the organization in order to shrink manufacturing cycle times, improve quality, and to respond to changing customer demands.
Cycle Time - Manual cycle time is the time needed for an operator to complete one work sequence to meet production. The Goal is to have Cycle time = Takt Time
Inventory Waste - Any supply in excess of a one-piece flow through your manufacturing process. Excess inventory increases the cost of the product by extra handling, extra space requirements, extra interest charges, extra people involvement, etc.
Just-In-Time (JIT) - A management philosophy aimed at eliminating waste from every aspect of manufacturing and its related activities. The term JIT refers to producing only what is needed, in just the amount it is needed, when it is needed.
Kaizen - Japanese word for continuous improvement.
Kanban System - An information system that controls (pulls) the production of the required parts in the required quantities and at the required time. Kanban is a manual (visual) system.
Lean Manufacturing/Production - A team based approach of manufacturing focused on identifying and eliminating waste through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection.
Non-Valued Added - Any activity that does not add market form or function or is not necessary. Any activity the customer is not willing to pay for. These activities should be eliminated, simplified, reduced or integrated.
One Piece Flow - Is based on the concept of having operators focus on transferring each item individually to the next process step. One-piece flow dramatically reduces handling and transportation and provides immediate feedback to any overlooked defect.
Over Production - Producing goods over and above the amount required by the market.
Poka-Yoke - Methods and low cost devices that prevent defective parts from being made or passed on in the process.
Processing Waste - Anything that uses resources, but does not add real value to the product or service.
Pull System - A method of controlling the flow of resources by replacing only what has been consumed.
Push System - Resources are provided to the consumer based on forecasts or schedules.
Quick Change - The ability to change tooling and fixtures rapidly so multiple products can be run on the same line/machine
Takt Time - Is the rate at which your customer requires the product. Takt time defines the manufacturing line speed and the cycle times for all manufacturing operations.(Takt Time = Available work time per day divided by the daily required customer demand in parts per day)
Total Productive Maintenance (TPM) - A concept of productive maintenance aimed at achieving overall effectiveness of the production system through the involvement of all the people in the organization.
Toyota Production System (TPS) - A manufacturing philosophy that shortens the time between customer order and shipment by eliminating waste.
Value Added - Any activity that increases the market form or function of the product or service. Things the customer is willing to pay for.
Value Stream Mapping - A visual method of documenting the material and information flows of a process.
Visual Factory/Controls - Displaying the status of an activity so every employee can see it and take appropriate action.
Work-In-Progress (WIP) - The amount of inventory already in the manufacturing process that has had value added to it.