Poka-yoke is a Japanese term that means ―to avoid inadvertent errors.‖ A poka-yoke device is one that prevents
incorrect parts from being
made or assembled, or identifies a flaw or error. Often referred to as error-proofing, poka-yoke is actually the first step in error-proofing a system. Error-proofing is a manufacturing technique of preventing errors by designing the manufacturing process, equipment, and tools so that an operation literally cannot be performed incorrectly (Munro, Ramu, & Zrymiak, 2015, p. 8). Among other things, it is a technique used to display information that can be quickly understood by everyone.
Error-proofing is the practice of striving for zero defects using techniques, standards, and device that prevent errors from being made. Examples of preventative measures include:
Error-proofing also uses shutdowns, controls, or warnings to detect errors and stop them before they become defects. Examples of detection measures include:
The key to effective error-proofing is determining when and where defect-causing conditions arise, then figuring out how to detect or prevent these conditions every time. (Munro, Ramu, & Zrymiak, 2015, p. 8)
Kanban means "visual board" in Japanese and in this context is a Japanese manufacturing system that uses instruction cards to track production. Review this approximately 10 minute read by Kanbanize, "Kanban Explained for Beginners".
Kaizen is a Sino-Japanese word for "improvement" and in this context is a concept referring to business activities that continuously improve all functions and involve all employees from the CEO to the assembly line workers. There are five fundamental principles:
"Blitz" means lightening fast. Kaizen blitz is a method to attack one problem and to do it quickly. It is also sometimes called a Kaizen event.
Kaizen often follows a path such as below:
The 5S structure can be used to identify and eliminate waste.
They literally stand for five "s" words - Japanese originally - and assist in work place organization and
standardization of work
procedures. The steps in this structure include:
A pull system is a lean manufacturing strategy used to reduce waste in the production process. In a push-based supply chain, products are pushed through the channel from production up to the retailers. In a pull-based supply chain, procurement, production, and distribution are demand-driven rather than based on predictions. Goods are produced in the amount and time needed (Koo, 2020). Another method is Constant Work in Progress (CONWIP) which is both push and pull.
A value stream map displays all the important steps of your work process necessary to deliver value from start to finish. It is also known as value stream analysis or lean process mapping. Review American Society for Quality What is Value Stream Mapping to learn more.
Kaizen Institute. (n.d.). What is Kaizen. Retrieved July 15, 2021 from https://www.kaizen.com/what-is-kaizen.html
Koo, J. (2020). Push System vs. Pull System. Tulip. Retrieved July 15, 2021 from https://tulip.co/blog/what-is-a-push-system-vs-a-pull-system/
Lean Manufacturing Tools (n.d.) OEE Calculation. Retrieved August 1, 2021 from https://leanmanufacturingtools.org/443/oee-calculation/
Lucidchart. (n.d.). The Best Lean Tools for Process Improvement. Retrieved July 9, 2021 from https://www.lucidchart.com/blog/best-lean-tools-for-process-improvement
Munro, R., Ramu, G., & Zrymiak, D. (2015). The Certified Six Sigma Green Belt Handbook. Retrieved July 12, 2021 from https://www.academia.edu/40442176/The_Certified_Six_Sigma_Green_Belt_Handbook_Second_Edition