Lean Manufacturing by the Numbers

Partridge in a Pear Tree?

Jon
I think you almost got the lot
You missed............
12 Mudas of Motion
6 sigma
5W1H
A3 Reporting
14 TPS Principles
Regards
Chris

0 = 7 from last post.

Good point Jaime!

Hi Chris,

I had left out A3 reports since if we got into the alphabet the list would be in the hundreds.

The 12 Mudas of Motion - this is new to me. Are these things like lifting, turning, searching, bending, and so forth or something else?

Wow! how many numbers! can you define some of them? for example i haven't heard anything about 3 don'ts of assembly and quality. or what is 16 catch phrases?

Hi Davod,

The three don'ts of assembly are:

1) Don't choose
2) Don't search
3) Don't turn around

These are direct translations from the Japanese, so others may call them something else.

The three don'ts of quality are:

1) Don't accept poor quality
2) Don't make poor quality
3) Don't pass on poor quality

Here is more on the 16 catch phrases.

Hi Jon

Sorry for the delay in replying to your question regarding the 12 Mudas of Motion.

You are correct in thinking that the 12 Mudas of Motion are associated with Ergonomics.

In RIPS (The Ricoh Production System)
The 12 Motion Mudas breakdown the 6th Muda waste, they are specifically aimed at improving light assembly work stations.

Here is a list

1.Waiting with both hands free
Both hands are not used during process

2.Waiting with one hand free
Waiting time while one hand is used for the process the other hand is not used for anything

3.Pausing
Pause between movements. (Eg. a pause to think before moving to the next process.)

4.Excessive Movement
Moving more than is necessary to do the work

5.Switching
Switch parts or tool from one hand to the other before the process begins

6.Walking
Additional walking due to distance between process area and parts/tools.

7.Turning Angle
Additional walking or turning due to parts location.

8.Wasted process by single operation
Non simultaneous operation even though it is possible to combine and operate more than 2 processes together

9.Rework. due to wrong operation
Rework due to process problem

10.Stretching.
Stretching due to higher location of parts or process

11.Bending.
Bending due to low location of parts or process.

12.Useless movement.
Movement with no added value such as confirmation movement, repeated movement, preparation movement, etc

Regards Chris

Thanks Chris. This is very useful.

pls mail details to me about
Zero inventory
Zero defects
Zero accidents
1 piece flow
1 point lesson
2 bin system
2 point control (AB control, full work control)
3D (dirty, dangerous, difficult)
3 elements of standard work (takt, work sequence, SWIP)
3 elements of JIT (takt, flow, pull)
3 gen (genchi, genbutsu, genjitsu)
3P (Production Preparation Process)
3 tei (set location, set quantity, set timing)
4M (man, material, machine, method)
5L (loose, lacking, 'lectrical, leaks, looks)
10 commandments
10 steps to jidoka
12 steps to TPM
16 catch phrases
30-30-30 (stand in the circle)
50 second rule of takt time
80/20 rule (Pareto Principle
5W1H
A3 Reporting
14 TPS Principles

Pls its urgent
thnkx

Very interesting list - thanks for all the posts/clarifications etc.

How can i evaluate risk assessment?

Dear Jon,
one more :
1(single) minute exchange of dies.
Thanks!

6M (Man, Material, Machine, Method, Measurement, Mother Nature)

Regarding SMED, a better translation from the original intent might be Single-digit Minute Exchange of Dies (i.e., less than 10 minutes), but over the years, a single minute has often become a realistic stretch goal.

Dear Jon and all,

I was interested with the lean manufacturing ny numbers, kindly send me the details of each of your most available time.

Kindly sent me first the details of 3 tei (set location, set quantity, set timing)