QCD 101 | For Assembly

Visualization Q: Create a situation where 4M changes, quality problems (in the line) of the day, past quality problems (in-coming and in-line quality), are easily observed. C: Cost & profit should be visible on a daily basis by controlling the profit by lines. D: By using inventory control plans, the inventory plans and the results […]

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QCD 101 | For the Shipping Area

Visualization Clearly Identify: what, how many pcs, where to, what time and which track. Clearly Identify: from which line or store, when, and how many pcs are pulled-in. Clearly Identify: shipping preparation hourly status. Visual Control Confirm the hourly status per the plan, and if any abnormality (delay) was observed, identify the cause and clearly […]

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QCD 101 | Finished Goods Store

Visualization Locations should be designated by products and production lines.  Inventory situation including inventory plans should be clearly visible. Visual Control Check the inventory to see if the amount meets the inventory plan.  If abnormality was observed, identify the cause and describe the counter measures on a control board. Supervisors should confirm the content on […]

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Study Guide – Toyota Way Fieldbook – VSM

Starting the Journey of Waste Reduction Part 3 Chapter 3 – VALUE STREAM MAPPING APPROACH By Swati Jadhav Recently I had a chance to read the book called The Toyota Way Fieldbook, by J. Liker and it changed my viewpoint towards Lean methodology. I used the guidelines provided by the book for the Value stream […]

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Toyota Way Fieldbook – “Study Guide”

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Overall, we have found the Fieldbook to be a great tool for those interested in “middle of the road” lean implementation.  Not “Big Picture” nor “Fine Detail”. For those interested in digging a little bit deeper for work or school… or for the Engineering Intern looking get a jump on a future career, we offer the […]

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BRAND NEW CONCEPT !!! …. JK

“Today’s standardization…is the necessary foundation on which tomorrow’s improvements will be based. If you think “standardization” as the best you know today, but which is to be improved tomorrow – you get somewhere. But if you think of standards as confining, then progress stops.” – Henry Ford in 1926

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I got no stink’in problem!

“Sometimes no problem is a sign of a different problem” – Mark Rosenthal, author of The Lean Thinker

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Keep it LOW!

“Due to the set-up times, the tendency is to produce in batches that are larger than the order quantities. This supposedly utilizes the equipment more efficiently, reduces set-up costs, and reduces unit product cost. But any production in excess of immediate market demand ends up as finished-goods inventory. The result of producing these large batches […]

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Ticking and Kicking By Mr. Miller

“Lean is about constant ticking, not occasional kicking.” – Alex Miller, Professor of Management at The University of Tennessee

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Shingo’s Barrage of Why’s!

“A relentless barrage of “why’s” is the best way to prepare your mind to pierce the clouded veil of thinking caused by the status quo. Use it often.” – Shigeo Shingo

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