Toolbox

• Balance Score Card
  The balanced scorecard is a strategic planning and management system that is used extensively in business and industry, government, and nonprofit organizations worldwide to align business activities to the vision and strategy of the organization, improve internal and external communications, and monitor organization performance against strategic goals.
• Value Stream Mapping (VSM)
  Value stream mapping is a lean manufacturing technique used to analyze the flow of materials and information currently required to bring a product or service to a consumer. At Toyota, where the technique originated, it is known as "material and information flow mapping"
• Quick Scan
  Quick Scan is a fast way to evaluate processes and determine the bottle necks and waste within an organisation.
• Makigami (visualiseer / analyseer voor kantoor)
  The Makigami process map, visualizes the current process in offices, laboratories, hospitals: Any place where the 'product' is not directly visible or physical.
• Kaizen
  Kaizen (Japanese for "improvement" or "change for the better") refers to a philosophy or practices that focus upon continuous improvement of processes in manufacturing, engineering, supporting business processes, and management. It has been applied in healthcare, government, banking, and many other industries. When used in the business sense and applied to the workplace, kaizen refers to activities that continually improve all functions, and involves all employees from the CEO to the assembly line workers. It also applies to processes, such as purchasing and logistics, that cross organizational boundaries into the supply chain.
• SGA (Small Group Activities)
  A Small Group Activity or Kaizen workshop is when a multifunctional team follows an eight step approach, from problem definition through to lasting improvement. The members of the team are both owners of the problem and capable of solving it.  Root cause analysis, standardisation and sustainment are key steps in the approach.
• SMED (Single Minute Exchange of Die)
  Single-Minute Exchange of Die (SMED) is one of the many lean production methods for reducing waste in a manufacturing process. It provides a rapid and efficient way of converting a manufacturing process from running the current product to running the next product. This rapid changeover is key to reducing production lot sizes and thereby improving flow (Mura).
• TPM
  Total productive maintenance (TPM) is a new way of looking at maintenance, or conversely, a reversion to old ways but on a mass scale. In TPM the machine operator performs much, and sometimes all, of the routine maintenance tasks themselves. This auto-maintenance ensures appropriate and effective efforts are expended since the machine is wholly the domain of one person or team. TPM is a critical adjunct to lean manufacturing.
• 5S Werkplekorganisatie
  '5S' is the name of a workplace organization methodology that uses a list of five Japanese words which are Seiri, Seiton, Seiso, Seiketsu and Shitsuke. transliterated and translated into English, start with the letter S. The list describes how items are stored and how the new order is maintained. The decision making process usually comes from a dialogue about standardization which builds a clear understanding among employees of how work should be done. It also instills ownership of the process in each employee.
• 5 why
  The 5 Whys is a question-asking method used to explore the cause/effect relationships underlying a particular problem. Ultimately, the goal of applying the 5 Whys method is to determine a root cause of a defect or problem.
• 7 forms of waste (MUDA)
• Overproduction
  Overproduction happens each time you engage more resources than needed to deliver to your customer. For instance, large batch production, because of long change over time, exceeds the strict quantity ordered by the customer. For productivity improvement, operators are required to produce more than the customer needs. Extra parts will be stored and not sold. Overproduction is the worst muda because it hides or generates all others, especially inventory.Overproduction increases the amount of space needed for storing raw material as well as finished goods. It also requires a preservation system.
• Unnecessary transportation
  Each time a product is moved it stands the risk of being damaged, lost, delayed, etc. as well as being a cost for no added value. Transportation does not make any transformation to the product that the consumer is supposed to pay for.
• Inventory
  Inventory, be it in the form of raw materials, work-in-progress (WIP), or finished goods, represents a capital outlay that has not yet produced an income either by the producer or for the consumer. Any of these three items not being actively processed to add value is waste.
• Motion
  As compared to Transportation, Motion refers to the producer, worker or equipment. This has significance to damage, wear and safety. It also includes the fixed assets and expenses incurred in the production process.
• Defects
  Whenever defects occur, extra costs are incurred reworking the part, rescheduling production, etc.
• Over-processing
  Over-processing occurs any time more work is done on a piece than what is required by the customer. This also includes using tools that are more precise, complex, or expensive than absolutely required.
• Waiting
  Whenever goods are not in transport or being processed, they are waiting. In traditional processes, a large part of an individual product's life is spent waiting to be worked on.
• FMEA
  A failure modes and effects analysis (FMEA), is a procedure in product development and operations management for analysis of potential failure modes within a system for classification by the severity and likelihood of the failures.
• SPC (Statistical Process Control)
  Statistical process control (SPC) is the application of statistical methods to the monitoring and control of a process to ensure that it operates at its full potential to produce conforming product. Under SPC, a process behaves predictably to produce as much conforming product as possible with the least possible waste.
• OEE (Overall Equipment Effectiveness)
  Overall equipment effectiveness (OEE) is a hierarchy of metrics which focus on how effectively a manufacturing operation is utilized. The results are stated in a generic form which allows comparison between manufacturing units in differing industries.
• APQP
  Advanced Product Quality Planning (or APQP) is a framework of procedures and techniques used to develop products in industry, particularly the automotive industry. It is quite similar to the concept of Design For Six Sigma (DFSS).
• PPAP
  'The Production Part Approval Process ('PPAP) is used in the automotive supply chain to establish confidence in component suppliers and their production processes, by demonstrating that:-"....all customer engineering design record and specification requirements are properly understood by the supplier and that the process has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate
• ISO 9001-2008
  Some of the requirements in ISO 9001:2008 (which is one of the standards in the ISO 9000 family) include
• a set of procedures that cover all key processes in the business;
• monitoring processes to ensure they are effective;
• keeping adequate records;
• checking output for defects, with appropriate and corrective action where necessary;
• regularly reviewing individual processes and the quality system itself for effectiveness; and
• facilitating continual improvement
• ISO/TS 16949
  The ISO/TS16949 is an international standard aiming to the development of a quality management system that provides for continual improvement, emphasizing defect prevention and the reduction of variation and waste in the supply chain.
• Publications
• http://www.springerlink.com/content/g7vx75h50238817k/
• Future manufacturing methods (to be published june 2010)