The Theory of Constraints relates any complex system, such as a manufacturing plant, to a set of one or two constraints which fix the upper limit on its performance. It seeks to manage those constraints to maximize the performance of the plant. The Theory of Constraints was developed by Dr. Eli Goldratt and first published in his book The Goal in 1984. … [Read more...]
A value stream map is a tool used in lean manufacturing to identify and communicate the value-producing processes within a factory. Value stream maps utilize a standard set of industry recognized symbols to map out the plant's processes, from raw material to finished product. Value stream maps are used to improve the plant's processes, perform continuous … [Read more...]
Value stream maps are diagrams used in lean manufacturing which identify each step of the manufacturing process. They are used to determine the value stream, that is, the steps that result in the creation of value. Their purpose is to visualize the manufacturing process so that anything that is not necessary to create the product of value can be … [Read more...]
Jidoka is the ability of machines and assembly line workers to detect when a quality non-conformance issue has occurred and immediately stop the production line to make the necessary improvements to the process. Jidoka originated in the Toyota Production System, where it was not just the worker's right to "pull the cord," but their responsibility. Far from leaving … [Read more...]
Human beings are naturally predisposed to resist change because of the risks it entails. Maybe the change will fail. Maybe it will reduce business or personal income. And maybe it will result in a loss of job security. We'd rather the devil we know, than the devil we don't. But process improvement is often an exciting step forward that makes an … [Read more...]
The definition of genius is taking the complex and making it simple. - Albert Einstein I have good news for you. If you are in the manufacturing business, you can become a genius today, right now. The shop floor can be a complex maze of raw materials moving in interlocking production lines, stations with varying cycle times, supply needs, and manpower … [Read more...]
If there is one enemy of business success, it is this: Wastefulness, inefficiency, and uselessness. This is the definition of the japanese word muda, a household name in lean manufacturing circles but an infinitely valuable one for every business professional who learns to root out and destroy this sprouting cancer at every available opportunity. In lean … [Read more...]
Takt time is a lean manufacturing concept which represents the exact rate at which a plant must produce its product to satisfy demand. It is measured in time per production step (minutes, hours, etc.). Although order levels fluctuate for many products and factories, the underlying demand tends to be constant. Hence, the production rate of the plant should … [Read more...]
Kaizen is a component of Lean Manufacturing which involves the steady, systematic removal of waste from the production line. In a lean facility, the components of the manufacturing process that produce value (the "value stream") are identified, and everything that is not absolutely necessary to produce that value is considered muda, japanese for waste. Kaizen, … [Read more...]
Poka Yoke is a component of lean manufacturing which involves error proofing of the production process. Like the square peg that doesn't fit into a round hole, it involves designing processes to eliminate the ability to produce poor quality products. Each task in a production process is inspected for defects. If the defects emerging from a task are particularly … [Read more...]
