BASIC

GLOSSARY
Lean Glossary of Terms

October 8, 2019 Confidential. Not to be copied, distributed, or reproduced without prior approval. 1
Basic Lean Glossary
5s Building Blocks for shop floor discipline and control; Sort, Set in Order, Shine,
Standardize, Sustain (Also known as Sort, Sweep, Standardize, Self Discipline,
Sustain).
Action Workout (Kaizen) 3-5 day team based activity focused on quickly solving problems through
physical simulation and evaluation.
Andon A visual device (light) or pin-pan-pon that operators use to call attention to an
abnormality. The use of this is to request immediate attention and action to the
problem.
Autonomation The process of separating the work of man and machine characterized by: work
not movement; quality built into the process; and visual management. (see Jidoka)
Cell The optimal physical layout or machines and manpower for a product or family of
products that identifies and eliminates waste.
Chaku-Chaku A method of conducting single-piece flow in which the operator proceeds from
machine to machine (in a counter-clockwise fashion), taking a part from the
previous operation and loading it in the next machine. Then taking the part just
removed from that machine, checking it and loading it into the following
machine…etc,…
Continuous Flow Carrying out one-piece-at-a-time production in order to eliminate stagnation of
Processing work (queue) in and between processing steps
(see Flow)
Cycle Time The total time required for a task to be complete. Elements include manual and
travel times, automated or machine run time.
Flow Work done simultaneous to or in conjunction with transportation or conveyance.
e.g. (1) an assembly is moving down a line while a person is performing work, (2) a
person acts as a conveyor carrying a part to the next machine in a Chaku-chaku
fashion. The main purpose of flow is to quickly and continuously identify and
eliminate waste.
Heijunka The process of level loading and sequencing the timing of production.
JIT (Just in time) theory of production characterized by (1) single piece flow, (2)
producing according to TAKT time, (3) pulling of material from upstream
process, keeping inventory at minimum, established levels.
Kaizen “Change for the better”; a process quality tool for improvement involving a
series of activities whereby instances of waste are eliminated one by one at
minimal cost, by workers pooling their ideas and increasing efficiency in a
timely manner. It emphasizes manual work operations rather than equipment.
(see action workout)
Kanban A method/device of pulling from previous processes in order to control material
flow, cap inventory levels, and to take “pulse” of the customer. It serves as: an
instruction for when to produce; a tool for visual control against over production
and a detection of irregular processing speeds. Kanban can be broadly
categorized into 2 categories: Production Kanban and Pick-up Kanban. These
can be further stratified into Ordinary, Signal, Transport, and Purchase.
Kitting Grouping component parts used in a process or build for ease of assembly. (
see material presentation )
Lead Time The total time it takes the product to go from raw inventory to the finished
product. Order to remittance lead time refers to the total time from when an
order is placed until the finished product is shipped.
Level Production Overall leveling in the production schedule of the variety and volume of items
produced in a given time period. ( see Heijunka)
Machine Time The time from machine switch on, processing, to machine returning to original
position, during which there is no hands-on work by the operator.
Manual Time The hands-on time it takes for the worker to perform a task.
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Basic Lean Glossary
Process Capacity Maximum amount of product that can be produced through a process for a given
Material Presentation Introducing material to the line or cell in a manner that is easy and effective for the period of time.
operator. Usually broken into 3 categories (1) items that are too large to kit (2) items
that are too small to kit (3) items that lend themselves to be kitted.
Process Capacity Indicates the maximum capacity for parts processing at any one process.
Table Recorded on it are: the amount of time spent in manual work, machine time,
setup time, etc.

Jidoka Machines that have “human intelligence” built into them, giving them the ability to
shut down automatically in the case of an abnormality to stop defective products Process Mapping A technique used to follow the detailed flow of a product through a manufacturing
from flowing into the next process. Jidoka measures are incorporated in the cycle.
assembly process by use of Andons and Pin-Pan-Pon; stopping when abnormality
is detected. Process Route A study of the process and machine sequence for a group of similar parts. It can
Analysis be used to standardize product flow for ease of cell implementations.

MUDA Any type of waste elements that add no value to the product:
i.e. Waiting, Transporting, Over production, Excess Motion, Inventory Defects,
Human Touches.
Process Quantity A study of the quantities demanded of different products produced at a work
Analysis location. This picture of the volume and variety of products can be used to
identify high impact areas to concentrate efforts or identify the need to use
One Piece Flow Production system in which only one part at a time is processed or assembled and process razing to make products more similar.
the work is verified before being sent along the production line to follow processes.

Pull System System of manufacturing in which each process withdraws the parts it needs
from the preceding process when they need them, in the exact standardized
Pin-Pan-Pon A form of Andon that is auditory…special sounds are designated to certain points amount needed.
on the line. e.g. A pin-pin-pin repeating sound may be associated with power
supply installation, calling attention to it when an abnormality has been detected.
Set-up, External Machine changeover steps that are performed while the machine is processing
parts or off-line from production time.

Poka yoke Mistake proof: usually refers to the use of fail-safe devices in the process in order
to prevent defects from occurring and insure quality. When this ingredient is added
to automation will yield autonomation. ( see Jidoka )
Process A series of steps to achieve a desired result.
Set-up, Internal Machine changeover steps that are performed while the machine is stopped
during production time.
Shingijutsu A company founded by C. Nakao and K. Iwata, former employees of Taiichi
Ohno, the creator of the Toyota Production System. The word Shingijutsu
translates as “new technology” or “better way”.

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Basic Lean Glossary
SMED Single Minute Exchange Die (i.e., under 10 min) has become a title for the category Takt Time Available production time / required production
of improvement devices used in manufacturing to allow for quick change over of
machine/fixture set-ups. TPM Total Productive Maintenance is the total involvement of all employees in a
cell to improve the process.

Standard Operations The combination of people and machines required to accomplish production in such
a way as to minimize waste. Value Stream The specific activities required to design, order, and provide a product from
concept to launch – order to delivery – raw materials to finished goods.

Standard WIP Minimum (and standardized) amount of work in process required to perform
repetitive operations economically.
Value Stream The process of detailing the process of converting raw material to finished
Mapping goods. This is typically mapped with the 7 flows (info, people, equipment,
Standard Work Sequence of repeatable tasks that an operator performs. raw material, sub-assembly, assembly,engineering) one at a time, or in a
combination.
Standard Work Sheet Shows the outline of work for each worker in a cell. Recorded on it are: Takt time,
work sequence, standard WIP, quality checks, safety precautions, etc.
Visual Management Refers to the means by which anyone can tell at a glance if production
activities are proceeding normally or not. A communication, discipline and
pacing tool.
Standard Work A table that clarifies how much time is spent doing manual work
Combination Sheet and traveling at each production process. It is used to examine
the range of processes that one worker can take care of within Waiting Time The time that a worker is idle when no work is available.
Takt time and the amount of time during which machines are operated
automatically. These are recorded to help determine WIP Work In Process; inventory of materials that has been already started
what combination of operations are possible. processing.

Work, Non-value Rework, set-ups, inspection, repair processing, transportation, unnecessary

Super Market A visual system that has a predetermined amount of inventory and all facets of 5s in
order to detect abnormalities. With this system, the shopper from the downstream
process can “buy” from the supermarket. Once the purchase has been made, and
material consumed, a signal can be sent to the upstream process to supply more.
(see pull)
added work to complete the manufacture of a product. Anything that isn’t directly
changing the form fit or function of the part.
Work, Value Added Only necessary direct work to manufacture a product. Anything that the
customer is willing to pay for or an operation that changes the form, fit, or
function of the part.

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