| cells |
An arrangement of machines, tooling, materials, and operators structured around the design of similar products. Cells encourage smooth product flows and use space efficiently. |
| cellular manufacturing |
A lean manufacturing method that uses specialized groupings of machines, people, and materials. |
| changeover time |
The non-value added time required to convert a setup for one product line to a setup for another product line. Changeover may require switching fixtures, tools, programming, and other aspects of the manufacturing process. |
| changeovers |
The time it takes to tear down the setup for the current product type, prepare for the next product type, and successfully produce the first good part. |
| cycle time |
The time it takes to perform a task and move to the next step. One of the major goals of lean manufacturing is to match cycle time to takt time. |
| ekanban |
An electronic kanban method used to signal production and material movement. Common ekanban methods include email or scanned barcodes. |
| error detection |
The inspection of a part during and after production to determine if errors have occurred. Error detection does not try to prevent errors. |
| error prevention |
A continuous improvement method that studies why and how errors occur. Error prevention creates ways to stop these problems from happening again. |
| external customers |
An outside organization or individual that receives a product or service from the company. |
| flow shop |
A manufacturing facility that produces one or two similar products using high-volume specialized equipment. An assembly line is an example of a flow shop. |
| in-process inspection |
The inspection of a part during production to detect errors. Errors that are detected early may allow the part to be reworked or may prevented from continuing through the manufacturing process. |
| internal customers |
A department or individual within the company that relies on others to satisfy the external customer. For any cell, the next cell in a process is always the internal customer. |
| inventory |
Temporary or long-term storage of parts or products that are either finished or in progress. With pull systems, inventory is reduced or eliminated. |
| job shop |
A manufacturing facility that produces several different products in smaller batches. A machine shop is a type of job shop. |
| just-in-time |
JIT. A lean approach to production in which materials and products are ready precisely when needed, thus reducing or eliminating inventory and in-process parts. |
| kaizen |
A Japanese word that means "change for the better." Kaizen is a combination of maintenance, problem solving, and innovation that is generally performed by a team. |
| kanban |
A Japanese word meaning "card signal." In pull systems, it represents any visual method used to show the need for parts or products to be moved or produced. |
| lean |
An approach to manufacturing that seeks to reduce the cycle time of processes, increase flexibility, and improve quality. Lean approaches help to eliminate waste in all its forms. |
| machine shop |
A factory or workshop where metal is cut and shaped by machines. A machine shop is a type of job shop. |
| material handling |
The strategy and devices used to move and store materials during the production cycle. Material handling should be minimized to reduce waste. |
| pokayoke |
A Japanese term meaning mistake proofing. Pokayoke is an error prevention method. |
| product families |
Groups of products that use similar machines or processes during manufacture. Grouping products according to family simplifies process flow charting. |
| project shop |
A manufacturing facility that produces large items by bringing the machines and materials to the project. |
| pull system |
A material management system in which parts are not delivered to machines until they are needed. Pull systems are based on actual demand for parts. |
| pull systems |
A material management system in which parts are not delivered to machines until they are needed. Pull systems are based on actual demand for parts. |
| push system |
A production method based on keeping up with preset inventory levels or with due dates for customer orders. Push systems are not based on customer demands. |
| retooling |
The changing of machinery, fixtures, and tools for the production of a new part. Retooling takes place before new product runs begin. |
| setup reduction |
A lean effort that uses standardization to reduce the time it takes to perform retooling. |
| soldering |
A joining method that uses a heated filler metal to create a joint between metal parts. The filler metal is melted at temperatures below 840° F (450° C). |
| takt time |
The ideal pace of production required to meet demand and consumption. Takt time is the number of work minutes per day divided by the number of work orders per day. |
| total productive maintenance |
TPM. An approach used in manufacturing to increase production and reduce all forms of waste. TPM involves continuous attention to the conditions of production machinery and facilities. |
| universal product codes |
UPC. A combination of a number and a series of parallel lines, known as a barcode, that appears on consumer packaging and is used in some shops as kanban. |
| waste |
Any thing or process that does not add value to a product. Scrap is the most common form of waste. |
| workholding |
The process of securely supporting, locating, and clamping a workpiece for a manufacturing operation. |