Lean manufacture专业名词解释

Term Definition
3M’s Man, machine, Material
3S’s Standardization, Simplification, Specialization
5 Why’s A method of problem solving that involves asking ”Why” a number of times until the root cause of a problem is determined.
5s Workplace Organization Process:
1) Sort (clear)
2) Straighten (Organize)
3) Sweep (Clean)
4) Standardize (maintain)
5) Sustain (Continuous Improvement)
6 Sigma Six sigma is a rigorous problem solving process focused on reducing variation and matching customer requirements to process capability .Six Sigma process knowledge enables achieving quality targets that maximize customer value
A3 One-page report format that includes all the information needed for the reader to:
* Make a decision on a stated PROPORSAL or PROBLEM, or Communicate the STATUS of or plans for a specific goal
Actual Runtime =(Scheduled Runtime)-(Downtime +Lost Time +Changeover Time)
Address System A standard logical alpha numeric system that identifies unique locations throughout the facility
Andon System A production Management visual/audio control tool, activated manually or automatically, to monitor status and to aid in emergency response by communicating to support resources the need for assistance
Area Information center An area on or near the manufacturing floor dedicated to providing proper communications for production personnel in a team environment
Autonomation A machine can stop itself by using its own judgement . Sometimes referred to as automation with a human touch
Beliefs and Values Group of statements that describe basic principles an organization embraces
Benchmark Standard by which a product, process, procedure etc. Can be measured or judged
Benchmarking Continuous systematic process for evaluation the products, services and work processes of organizations that are recognized as representing the best practices for the purpose of organizational improvement
Bulk Storage See Supermarket /bulk
Card Pull A system that uses a “Production Card “to authorize build of parts and “Withdrawal Card” to authorize the movement/shipment of parts
Changeover Time Production time lost due to part number changeover
Clean (sweep) Process that requires inspection and evaluation for the work area for dirt , debris and fluid leaks and ensures that irreversible corrective actions are implemented where needed.
Clear (sort) Requires that everything stored at the workstation is used on a frequent basis and that everything else is stored away from the workstation
Common Lot Strategy Reducing variation in the material flow pipeline through the use of factors of sixty standard pack/standard lot quantities.(60,30,20,15,12,10,6,5,4,3,2,1)
Communication Model Structured process for information sharing and exchange that is implemented and understood by the whole organization
7 waste Correction
Overproduction
Material movement
Motion
Waiting
Inventory
Processing
Constraint That bottleneck which most severely limits the organization from achieving higher performance towards its goal or purpose
Constraints managements A tool which enables the organization to quickly focus improvement efforts in a specific area
Container or dolly exchange pull system Material pull system that uses an empty container or dolly as a physical signal that authorizes the supplier to replace the amount of material consumed.
Container return process The orderly process of collecting, sorting ,staging and returning damage free reusable containers and dunnage in a timely manner to suppliers
Containerization Packaging parts in the smallest lot possible resulting in the presentation of a quality part in a manner that eliminates the waste of motion for the operator
Continuous improvement process Systematic approach that leads to the identification and elimination fo waste and to improved levels of performance
Daily production report A hard copy version of the production status board which should be used in every production area
Delivery pull See withdrawal pull
Delivery routes See internal delivery
Delphi manufacturing system A flow based structure manufacturing system designed to transform and continuously improve operations to support customer needs.
Delphi product development process (PDP) Provides a structured process to effectively design, develop and implement new products and .or processes to meet customer requirements.
Design for manufacturability machine and tool design(DFM-M&TD) An initiative to analyze and improve the design of tools , equipment and process from a life cycle cost perspective.
DGP Delphi global purchasing
Downtime Production time lost due to equipment only
Education and training A formalized training plan based on a structured method of identifying training needs to support continuous improvement
Effective available minutes =(minutes per shift)-(approved breaks)
Electronic pull A system using electronic signal generated by keypunch, scaning or electronic sensor to signal the need for material replenishment at a predetermined reorder point
Elimination of waste The process of identifying and eliminating the seven forms of waste
Emergency maintenance Function of quickly responding to and repairing a job when maintenance is signaled, having all of the skills equipment and parts available to repair the emergency breakdown instantly and efficiently without barriers or roadblocks
Employee environment and involvement All people within an organization working as a team to continuously improve and accomplish the manufacturing objectives.
Empty container storage Designated area to store returnable containers received from customers and /or staged for shipment to suppliers
Error proofing Process of anticipating, preventing and detecting errors which adversely affect customers and /or result in waste
Escalationg procedure An established documented and understood standard progression of events that is developed to address lost time and downtime response.
External pull See supplier pull
External setup Changeover steps that can be performed while a machine is running
Flow manufacturing A time-based process that pulls material through a production system with no interruption at the rate of customer demand
Gap assessment Process for consistent measurement and evaluation of DMS implementation
Hazardous material plan Required so that material in our plants is handled in the appropriate manner to ensure the health and safety of our workforce
Heijunka See level scheduling
Indirect material plan Required so that material in our plants is handled in the appropriate manner to ensure the health and safety of our workforce
Internal audits Audits performed by an organization on itself using its own personnel
Internal delivery routes A system to replenish/remove empty containers and material based on a predetermined delivery path and fixed start times supporting pull delivery to a specific number of production delivery points of use
Internal setup Change over steps that must be performed while the machine is stopped
Inventory turns An inventory measure obtained by dividing annual sales at cost by the average aggregate inventory value maintained during the year. FORMULA__inventory turens=annual sales (at cost)/Average inventory value
Jidoka See autonomation
Just-in-time production (JIT) See flow manufacturing
Kaizen Japanese term for continuous improvement
Kanban See card pull
Kanban post The box or board that is used to collect pull cards.
Kitting A process of grouping parts into sets that are used together in a downstream operation
Lead time See total product cycle time
Lean logistics A closed loop system of material delivery and container return from supplier to customers managed by a lead logistics supplier (LLP)
Level scheduling See production leveling
Linear cycle time The pace at which all machines must be capable of running
Lost time All reasons for production loss not included in downtime and changeover time
Lot size pull A material pull system that uses a single pull signal to indicate the size of a lot that should be produced and when it should be produced
Machine process capability Analysis tool used to evaluate stability and natural control limits of a machine or process compared to the specifications
Machine qualification Validation of new or modified production equipment by performance testing
Machinery and equipment specifications Together with appropriate standards describes the requirements to be met by equipment and supplies.OA-8 Especifications de maquinariay equipo
Maintain(standardize) Standard systems (labels ,documented and understood standard progression of events that is developed to address lost time and downtime response, color coding etc.)that readily identify abnormal conditions
Maintainability A characteristic of design, installation and operation, usually expressed as the probability that a machine can be retained in ,or restored to ,specified operable condition within a specified interval of time when maintenance is performed as prescribed.
Maintenance parts kitting Process of organizing all components necessary to complete a work order into one container.
MAPS Problem solving process used to identify, analyze and eliminate the gap between our current and desired state to achieve customer satisfaction
Material movement A process that effectively moves material through the manufacturing operations to support flow strategy resulting in the delivery of the required quantity of product to the customer on time
Measurement system analysis Performed to determine if the measurement system possesses the required statistical properties and to discover which, if any ,environmental factors have significant influence on the measurement system
Measurement /feedback system Methods of communication that are utilized to provide a common understanding of information throughout the organization
Mixed model production See production leveling
MSD Manufacturing system design(see flow manufacturing)
Muda Japanese term for waste
Mura Japanese term for fluctuation
Muri Japanese term for unreasonable practices
Natural work group structure and support Small groups of employees geographically close interact with each other and share operational and continuous improvement tasks to achieve the common goal of customer satisfaction
Office workplace organization Application of the 5 step workplace organization process to the office environment
One piece flow production Moving parts through a production system one piece at a time with no inventory in-between each operation.
Operational availability(OA) =actual runtime/scheduled runtime ╳1000
Operator certification process Ensures that operators have the knowledge, skills and abilities necessary to safely and efficiently operate the equipment to which they are assigned
Operator work envelope The area in which an operator can work in a safe ,comfortable and efficient manner
Organize(straighten) Process that arranges all of the materials left after the clear cycle in a manner that ensures safety, quality, reduced ergonomic stress, an orderly sequence and minimal operator motion
OSKKK Observation, Standardization, Kaizen the (Flow/Process, Equipment, Layout)
Overburden Results when a machine or worker is pushed beyond the natural limit of their capacity
Owner/operator concept The mindset that the operator of the machine assumes the role of owner with primary responsibility for maintaining and improving the operational condition of the machinery and equipment
Part presentation Displays parts to the operator so they are easy to see, easy to get and easy to return
People focused practice workshop Process that allow the NATUAL WORK GROUP (team) to express opinions and proposals for improvement and development of their people focused practices
People focused practices(PFP) A process that facilitates the design of an integrated process that provides operators efficient and safe operations
People recognition system Designed to recognize people and teams whose behavior exemplifies the “beliefs and values” of Delphi Automotive Systems and contributes to quality and customer satisfaction through improvements and development of their people focused practice
Plan for every part(PFEP) A material planning process that identifies/creates a detailed plan for every part in an electronic data base for all aspects of the material movement system.
Planned cycle time(PCT) A modification to TAKT TIME based on targeted operational availability and quality load factors
Planned downtime The amount of time an operation is down for scheduled reasons
Planned maintenance(PM) Total system of activities in which all employees work to increase uptime, to improve quality of output, safety and to reduce plant costs through continuous improvement of equipment operation
Plant communication center Area in the facility accessible to all employees utilized for displaying the current status of DMS implementation
Plant wide safety policy States the plant specific views on health and safety beyond those stated in the Delphi and divisional health and safety policies.
PM Preventative maintenance
Poka-yoke See error proofing
Process control Group of activities performed by the plant to ensure the customer receives products that exceed their requirements.
Process failure mode and effects analysis(PFMEA) An analytical technique utilized by a process engineer /team as a means to insure that ,to the extent possible ,potential failure modes and their associated causes have been considered and addressed.
Process flow chart A tool designed to identify, classify, quantify, and subsequently support the elimination of waste.
Process validation Collection of activities that when performed properly ,will ensure that the system meets specific requirements
Production leveling A technique that buffers the internal manufacturing process ( usually final assembly) to build into a calculated finished goods inventory based on a repeatable cadence.
Production pull Use of a pull system to authorize manufacture or assembly of component parts or finished product at the request of the next point of use.
Production pull board A board used to sequence production using pull cards.
Production reporting A system designed to improve how a manufacturing system operates through the collection and interpretation of data
Production status board Visual tool in the production area that the natural workgroup (team) uses to record, understand and communicate how their operation is running
Protect the customer Consists of a group of activities which collectively ensure that the customer receives products meeting their requirements when quality issues are anticipated or have occurred.
Pull card system See card pull
Pull system A method of controlling the flow of resources by replacing only what has been consumed.
Quality control The process of ensuring that established goals are met including the detection of departures from planned levels of performance and the restoration of performance to those planned levels.
Quality improvement The activity of improving quality performance to new and unprecedented levels.
Quality leadership The demonstration of a high level of commitment and involvement of a leader and staff to the successful implementation and maintenance of the Delphi quality management process.
Quality load factor The amount of extra product that must be produced to compensate for scrap downstream of the process and/or rework that is sent through the process.
Quality management process Consists of the organizational structure, responsibilities, procedures, process, resources and culture required to take our customer requirements and translate them into processes that produce products which develop customer enthusiasm by exceeding their expectations.
Quality planning Process of identifying customer requirements and developing products and processes necessary to exceed customer expectations
Quality system See quality management process
Quality system requirements (QS9000/ISO9000) Defines the fundamental quality system expectations for an organization, including qualify planning, quality control, and quality involvement
Quick response A production response system that facilitates immediate resolution to lost time and downtime issues by alerting the appropriate support group.
Quick Set-up/Changeover Absolute minimum amount of time to change over from one activity to another, to minimize the amount of time equipment remains idle, thereby responding faster to customer needs
Redeployment policy An agreement to provide displaced employees meaningful work opportunities
Reliability The probability the machinery and equipment can perform continuously , without failure, for a specified interval of time when operating under stated conditions and maintainability workshop quality network based training course developed to teach cross-functional design teams a structured methodology to identify and incorporate features into tooling and equipment designs that improve reliability and maintainability
Repacking The process of transferring parts from one container into a more appropriate size or type of container to satisfy the needs of the next using customer.
Scheduled run time =(Effective minutes)-(planned downtime)
Scheduled window receiving A specific dock schedule allocating days and times of day for delivery of purchased material and pick-up of empty returnable containers.
Scheduled window shipping A specific dock schedule allocating days and times of day for delivery of purchased goods containers and pick-up of finished goods.
Scientific method of problem solving A five steps method of problem solving: 1, Identify; 2, analyze; 3, plan; 4, implement; 5, evaluate.
SDE Supplier development engineer
Sequencing A process of arranging like parts into a build sequence for delivery to the manufacturing
Shakedown run Internal process validation designed to check that the entire manufacturing system is ready for production.
Small lot Fever number of parts to be moved from one process to another process. The ultimate goal is to move one part at a time.
Standard work See people focused practices.
Standard work in process (SWIP) The minimum number of work pieces necessary to perform the work sequence.
Supermarket/bulk Storage An area utilized to store material inventory( purchased ,in process and finished , both hand carriable and bulk).
Supplier pull A process that authorizes replenishment of material from suppliers based on consumption using a pull signal.
Supplier quality management Process that identifies and documents requirements for suppliers that supply purchased parts to Delphi Automotive System
Takt time Cycle rate at which production should run to meet customer damand . It is a calculated increment of time that should reflect the rate at which a customer requires a part relative to the operating time of a line or piece of equipment.
Total product cycle The longest lead time path(critical path) from receiving raw materials to shipping finished
Total productive maintenance(TPM) A concept of productive maintenance aimed at achieving overall effectiveness of the production system through the involvement of all the people in the organization.
Tugger route A material replenishment system based on a predetermined delivery path to a specific number of production operations . uses a timed loop to bring material to the line on a small motorized cart in small lots.
Unevenness Those variations in production volumes driven by poor planning and scheduling. Those variations in the amount of work done by a worker or machine and the flow of product in and out of operations.
Value stream Includes all elements(both value and non-value added) that occur to a given product from its inception as a raw material through delivery to the customer
Value stream mapping A hands-on process of documenting value stream material and information flow in a graphical form using icons.
Value-added Describes operations whose performance increase the value of materials
Visual control Job related visual and audio signals that are readily apparent and can be easily understood. This information can be used to identify ,instruct, or indicate that nomal or abnormal conditions exist and that action may be required
Warranty improvement Process for identifying opportunities , prioritizing projects, and correcting problems associated with warranties.
Waste Anything that does not directly add value to the final product or contribute to the products transformation
Withdrawal pull Use of a pull system to authorize movement of material from storage to production point of use.
Workplace organization A visual management system that facilitates the flow of product and information through application of standard practices