PDCA is a four-step methodology for problem-solving. PDCA stands for Plan Do Check Act/Adjust. It can also stand for Plan Do Study Act. This methodology can be used continually to improve processes. Plan: Plan or outline a problem. Do: Do or apply countermeasure to address root cause. Check: Check or…
Takt is translated from the German word Taktzeit or “clock interval” meaning pace of production. Takt Time is the average time between the completion of one unit and the completion of the next. It’s used to determine whether or not a process can keep up with customer demand. Takt Time…
Pull systems refer to the goal of having units "pulled" through the process at the rate of customer demand. The opposite of a Pull system is a "Push" system in which goods or services are prepared ahead of time potentially resulting in excess inventory or increased waste. JIT (Just In…
Poka-yoke is a Japanese term (poka: mistakes; yokeru: avoid) that means to mistake-proof a process. The goal is to consciously and diligently try to eliminate defects by preventing human errors before they occur or create alarms to warn of potential defects. For a better understanding of Poka-yoke and an overview of…
Kanban is a Japanese term that translates to "card" or “board” and indicates some form of signal within a process. Kanbans are part of Just In Time (JIT) processing where either a physical or electronic device indicates that it’s time to order inventory, process a unit or move to the…
Andon is an alert system that can be visual or audible, facilitating quick response to any problems in the process or system. This system includes a way for employees to stop the process, physically or electronically, so that the issue can be addressed before production continues. For a better understanding…
What is a Value-Added Flow Analysis? Value-Added Flow Analysis combines two powerful tools into one. The Value Analysis differentiates steps that add value in the eyes of the customer from those that do not, and Flow Analysis calculates the time spent on each step. This makes clear the time and…