Total Productive Maintenance and Lean Manufacturing

Vocabulary flashcards covering core concepts of Total Productive Maintenance, 5S methodology, Lean wastes, mistake-proofing systems, and implementation action plans.

Lean

An elimination of waste in operations through managerial principles.

Muda

The Japanese word for waste, commonly used when discussing Lean.

5S Method

A method that allows organization and cleaning of workstations to eliminate unnecessary mistakes through Sort, Set in order, Shine, Standardize, and Sustain.

Seiri (Sorting)

The first step of 5S aimed at eliminating unnecessary items and keeping only necessary items based on frequency of use.

RED TAG

A tag attached to items considered unnecessary or doubtful during Seiri, kept for a certain period of time to determine if needed before disposal.

Seiton (Organizing)

The second step of 5S that determines the best placement or layout so items are immediately accessible whenever necessary.

Seiso (Cleaning)

The third step of 5S focused on eliminating waste, dirt, or foreign matter and inspecting equipment using senses to discover malfunctions.

Seiketsu (Standardizing)

The fourth step of 5S aimed at standardizing activities in Seiri, Seiton, and Seiso so they are repeated and thoroughly executed to maintain a clean environment.

Shitsuke (Self-Discipline)

The fifth step of 5S that turns 4S activities into a habit and establishes adherence to rules as second nature.

Visual Management (VM)

A system using visual cues, signage, electronic displays, labeling, and shadow boards to distinguish normal conditions from abnormal ones at a glance.

Control System (Mistake Proofing)

A mistake proofing approach that stops equipment when a defect or unexpected event occurs, preventing the next step in the process from executing.

Warning System (Mistake Proofing)

A mistake proofing approach that signals operators to stop the process or address an issue at the time it occurs.

Seven Wastes

The key categories of waste in manufacturing: Over-Production, Waiting, Transport, Over-Processing, Inventory, Movement, and Defect and Rework.

DOWNTIME

An acronym representing eight wastes in Lean: Defect/correction, Overproduction, Waiting, Not utilizing employee talent, Transportation/material movement, Inventory, Motion, and Excessive processing.

Pull System

The practice of not producing any goods upstream if the downstream customer does not need it.

Push System

A system where products are pushed through the channel from production up to retailers based on a demand forecast.

Lean Action Plan Step 1

Getting started by planning out the appropriate steps, which takes 1 to 6 months.

Lean Action Plan Step 2

Creating the new organization and restructuring, which takes 6 to 24 months.

Lean Action Plan Step 3

Implementing Lean techniques and systems and continually improving, which takes 2 to 4 years.

Lean Action Plan Step 4

Completing the transformation, which takes up to 5 years.