Lean Manufacturing by the Numbers

Lean manufacturing by the numbers:
Zero inventory
Zero defects
Zero accidents
1 piece flow
1 point lesson
2 bin system
2 point control (AB control, full work control)
3D (dirty, dangerous, difficult)
3 don’ts of assembly
3 don’ts of quality
3 elements of standard work (takt, work sequence, SWIP)
3 elements of JIT (takt, flow, pull)
3 gen (genchi, genbutsu, genjitsu)
3P (Production Preparation Process)
3 tei (set location, set quantity, set timing)
4M (man, material, machine, method)
5L (loose, lacking, ‘lectrical, leaks, looks)
5S
5 why
6 big losses
7 new tools
7 steps of autonomous maintenance
7 wastes
7 ways (7 alternatives)
7 QC tools
8D problem solving
10 commandments
10 steps to jidoka
12 steps to TPM
16 catch phrases
30-30-30 (stand in the circle)
50 second rule of takt time
80/20 rule (Pareto Principle)
What did I miss?

15 Comments

  1. Steve

    May 17, 2007 - 1:52 pm

    Partridge in a Pear Tree?

  2. Chris Nicholls

    May 18, 2007 - 12:45 am

    Jon
    I think you almost got the lot
    You missed…………
    12 Mudas of Motion
    6 sigma
    5W1H
    A3 Reporting
    14 TPS Principles
    Regards
    Chris

  3. Jaime

    May 18, 2007 - 7:47 am

    0 = 7 from last post.

  4. Jon Miller

    May 18, 2007 - 8:38 am

    Good point Jaime!

  5. Jon Miller

    May 18, 2007 - 8:43 am

    Hi Chris,
    I had left out A3 reports since if we got into the alphabet the list would be in the hundreds.
    The 12 Mudas of Motion – this is new to me. Are these things like lifting, turning, searching, bending, and so forth or something else?

  6. Davod Ebrahimi

    May 18, 2007 - 12:11 pm

    Wow! how many numbers! can you define some of them? for example i haven’t heard anything about 3 don’ts of assembly and quality. or what is 16 catch phrases?

  7. Jon Miller

    May 18, 2007 - 12:42 pm

    Hi Davod,
    The three don’ts of assembly are:
    1) Don’t choose
    2) Don’t search
    3) Don’t turn around
    These are direct translations from the Japanese, so others may call them something else.
    The three don’ts of quality are:
    1) Don’t accept poor quality
    2) Don’t make poor quality
    3) Don’t pass on poor quality
    Here is more on the 16 catch phrases.

  8. Chris Nicholls

    May 23, 2007 - 1:20 am

    Hi Jon
    Sorry for the delay in replying to your question regarding the 12 Mudas of Motion.
    You are correct in thinking that the 12 Mudas of Motion are associated with Ergonomics.
    In RIPS (The Ricoh Production System)
    The 12 Motion Mudas breakdown the 6th Muda waste, they are specifically aimed at improving light assembly work stations.
    Here is a list
    1.Waiting with both hands free
    Both hands are not used during process
    2.Waiting with one hand free
    Waiting time while one hand is used for the process the other hand is not used for anything
    3.Pausing
    Pause between movements. (Eg. a pause to think before moving to the next process.)
    4.Excessive Movement
    Moving more than is necessary to do the work
    5.Switching
    Switch parts or tool from one hand to the other before the process begins
    6.Walking
    Additional walking due to distance between process area and parts/tools.
    7.Turning Angle
    Additional walking or turning due to parts location.
    8.Wasted process by single operation
    Non simultaneous operation even though it is possible to combine and operate more than 2 processes together
    9.Rework. due to wrong operation
    Rework due to process problem
    10.Stretching.
    Stretching due to higher location of parts or process
    11.Bending.
    Bending due to low location of parts or process.
    12.Useless movement.
    Movement with no added value such as confirmation movement, repeated movement, preparation movement, etc
    Regards Chris

  9. Jon

    May 23, 2007 - 10:49 am

    Thanks Chris. This is very useful.

  10. uttam singh

    June 19, 2007 - 12:21 am

    pls mail details to me about
    Zero inventory
    Zero defects
    Zero accidents
    1 piece flow
    1 point lesson
    2 bin system
    2 point control (AB control, full work control)
    3D (dirty, dangerous, difficult)
    3 elements of standard work (takt, work sequence, SWIP)
    3 elements of JIT (takt, flow, pull)
    3 gen (genchi, genbutsu, genjitsu)
    3P (Production Preparation Process)
    3 tei (set location, set quantity, set timing)
    4M (man, material, machine, method)
    5L (loose, lacking, ‘lectrical, leaks, looks)
    10 commandments
    10 steps to jidoka
    12 steps to TPM
    16 catch phrases
    30-30-30 (stand in the circle)
    50 second rule of takt time
    80/20 rule (Pareto Principle
    5W1H
    A3 Reporting
    14 TPS Principles
    Pls its urgent
    thnkx

  11. Andy Nichols

    September 10, 2007 - 4:41 am

    Very interesting list – thanks for all the posts/clarifications etc.

  12. Brad

    October 30, 2008 - 1:03 am

    How can i evaluate risk assessment?

  13. sharma

    December 30, 2009 - 4:09 am

    Dear Jon,
    one more :
    1(single) minute exchange of dies.
    Thanks!

  14. Larry Graham

    August 9, 2010 - 11:38 am

    6M (Man, Material, Machine, Method, Measurement, Mother Nature)
    Regarding SMED, a better translation from the original intent might be Single-digit Minute Exchange of Dies (i.e., less than 10 minutes), but over the years, a single minute has often become a realistic stretch goal.

  15. Yolly Rupido

    May 30, 2011 - 8:11 pm

    Dear Jon and all,
    I was interested with the lean manufacturing ny numbers, kindly send me the details of each of your most available time.
    Kindly sent me first the details of 3 tei (set location, set quantity, set timing)