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Lean Glossary

Lean Glossary

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A set of techniques, originally pioneered by Denso in the Toyota
Group in Japan, to ensure that every machine in a production
process always is able to perform its required tasks.

The approach is termed totalin three senses. First, it requires the
total participation of all employees, not only maintenance personnel
but line managers, manufacturing engineers, quality experts, and
operators. Second, it seeks total productivity of equipment by
focusing on all of the six major losses that plague equipment:
downtime, changeover time, minor stops, speed losses, scrap,
and rework. Third, it addresses the total life cycle of equipment
to revise maintenance practices, activities, and improvements in
relation to where equipment is in its life cycle.

Theory of Constraints (TOC)

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Unlike traditional preventive maintenance, which relies on
maintenance personnel, TPM involves operators in routine
maintenance, improvement projects, and simple repairs. For
example, operators perform daily activities such as lubricating,
cleaning, tightening, and inspecting equipment.

See:Overall Equipment Effectiveness (OEE).

Total Quality Control (TQC)

A management approach in which all departments, employees, and
managers are responsible for continuously improving quality so
that products and services meet or exceed customer expectations.

The TQC methodology relies on the plan-do-check-act (PDCA) cycle
to manage processes and, when problems arise, statistical tools to
solve them. The methodology and tools are used often by employees
during kaizen activities and together form an important subsystem
of lean.

The term “total quality control” was coined in 1957 by U.S. quality
expert Armand Feigenbaum, who saw quality control professionals
as central to promoting TQC. By the 1980s, other experts such as
Philip Crosby, Joseph Juran, W. Edwards Deming, and Kaoru
Ishikawa expanded the concept, now known as Total Quality
Management, to include new tools and, most importantly, the idea
that quality was the responsibility of all employees, managers, and
senior managers.

Toyota implemented TQC in the early 1960s and began transferring
the system to suppliers in the late 1960s.

See: Plan Do Check Act, Toyota Production System.

Total Quality Management

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