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A mistake proofing device or procedure to prevent a defect during order-taking or manufacture.
Poka-yoke is designed to stop the movement of a component to the next station by using "fail-safing" techniques to eliminate errors or quality-related production defects as far upstream in the process as possible.
Example: requiring completed components to pass through a customized opening to ensure that dimensions do not exceed tolerance limits. Also includes methods to check equipment operating conditions prior to making a part. A major objective is to minimize the need for rework.
Policy Deployment -
Unifies and aligns resources and establishes clearly measurable targets against which progress toward the key objectives is measured on a regular basis.
Predictive Maintenance -
Practices that seek to prevent unscheduled machinery downtime by collecting and analyzing data on equipment conditions. The analysis is then used to predict time-to-failure, plan maintenance, and restore machinery to good operating condition.
Predictive maintenance systems typically measure parameters on machine operations, such as vibration, heat, pressure, noise, and lubricant condition. In conjunction with computerized maintenance management systems (CMMS), predictive maintenance enables repair-work orders to be released automatically, repair-parts inventories checked, or routine maintenance scheduled.
Problem solving methodoligies explained
A variety of approaches to problem solving, including the Deming Circle (Plan-Do-Check-Act), used by all persons working in the same team or organization. Considered fundamental to teamwork.
Process -
A series of individual operations required to create a design, completed order, or product.
Processing Time -
The time a product is actually being worked on in design or production and the time an order is actually being processed. Typically, processing time is a small fraction of throughput time and lead time.
Productivity Increase -
The primary definition here is "the plantwide increase in annual value-added per employee, based on total employment in the plant, not just direct labour".
Value-added should be calculated by subtracting cost of purchased materials and services from value of shipments.
The Best Plants entry form also includes a secondary calculation, which many manufacturers prefer to use: "increase in sales per employee." Where possible, Best Plants candidates should compute and report five-year productivity increases using both calculations.
Pull -
A system of cascading production and delivery instructions from downstream to upstream activities in which nothing is produced by the upstream supplier until the downstream customer signals a need.
Pull System -
A system for controlling work flow and priorities whereby the processes needing materials (or attention) draw them from the feeding processes or storage areas as needed, typically using "kanban" signals in contrast to "push" systems in which material is processed, then pushed to the next stage whether or not it is really needed.
QFD (Quality Function Deployment) -
A customer-focused approach to quality improvement in which customer needs (desired product or service characteristics) are analyzed at the design stage and translated into specific product-and process- design requirements for the supplier organization.
Targeted customer needs may include product features, cost, durability, and other product characteristics.
QFD involves carefully listening to the customer's true unvarnished expression of their needs. Then those needs must be translated into engineering characteristics, competitive assessment, selection of critical/key characteristics, the product/process design, and follow-up.
Through this technique, product performance features and the characteristics that deliver them are determined by the customer and paid heed to by the producer (by listening and acting). The quality responsibility is then deployed throughout the organization by tying compliance activities directly to the fulfillment of these customer requirements.
Quick Changeover Methods -
A variety of techniques, such as SMED (single- minute exchange of dies), which reduce equipment setup time and permit more frequent setups, thus improving flexibility and reducing lot sizes and leadtimes.
Route Map
Strategic planning tool used to translate the goals and vision of an organization into a long term workable strategic plan.
SDCA Cycle (standardize, do, check, action) -
a refinement of the PDCA Cycle wherein management decides first to establish the standard before performing the regular PDCA function.
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