What is Autonomation

Autonomation:
Described as “intelligent automation” or “automation with a human touch.” If an abnormal situation arises the machine stops and the worker will stop the production line. Prevents the production of defective products, eliminates overproduction and focuses attention on understanding the problem and ensuring that it never recurs.
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Originally posted 2012-08-26 07:14:00.

Policy Deployment – Benifits of planning and executing

Policy Deployment: 
A one year plan, reflecting the long-term vision and the 3-5 year strategic planning objectives. A planning/implementation process that focuses on a few, major, long term, customer focused breakthrough objectives that are critical to a company’s long term success. This process links major objectives with specific support plans throughout the organization. Strategic Planning/Strategic Management methodology, developed by Dr. Yoji Akao. Also known as Hoshin Kanri.
Various Terms used in this methodology are
Annual Objectives:
In Policy Deployment, those current year objectives that will allow you to reach your 3-5 year breakthrough objectives.
Bowling Chart
A form used to track performance (plan vs actual) on Policy Deployment objectives. Usually reviewed with top management on a monthly basis.
Breakthrough Objectives:
In Policy Deployment, those objectives characterized by multi-functional teamwork, significant change in the organization, significant competitive advantage and major stretch for the organization.
Catch Ball
The process of selecting strategies to meet an objective at any level then getting managers and their teams to engage in dialogue to reach agreement on strategies to achieve their goals.
Key Performance Indicators (K.P.I.)
A method of tracking or monitoring the progress of existing daily management systems
Policy Deployment Action Plan
Form used by the team working on a PD objective, detailing specific activities required for success, milestones, responsibilities and due dates. Team members are also listed with objective definition, meeting dates and management support or owner.
Policy Deployment Matrix
Form used to show relationships between 3-5 year objectives, improvement priorities, targets, resources required and benefits to the organization
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Originally posted 2012-08-26 07:12:00.

What is Andon

Andon – Definition
A device that calls attention to defects, equipment abnormalities, other problems, or reports the status and needs of a system typically by means of lights – red light for failure mode, amber light to show marginal performance, and a green light for normal operation mode.
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Originally posted 2012-08-26 07:00:00.

Affinity diagram and Fish bone diagram

These Quality Control tools are used in problem Solving as a visual methods such as Affinity diagram and  Fish bone diagram. These are used in some lean programs also to make sure value stream and value addition.
Affinity Diagram: – Definition
A process to organize disparate language info by placing it on cards and grouping the cards that go together in a creative way. “header” cards are then used to summarize each group of cards.
Cause and Effect Diagram
A problem-solving tool used to show relationships between effects and multiple causes.
CEDAC
Acronym for Cause and Effect Diagram with the Addition of Cards. CEDAC is a method for involving team members in the problem solving process.

Fishbone Diagram  A chart that resembles a fish skeleton, with a main spine and branches (bones) drawn at a slant off the spine; used for quality control in two main ways:
1. As a cause-and-effect diagram, where the spine denotes an effect and the branches are cause factors.
2. As a subdivision of quality requirements, where the spine represents a quality objective and the branches describe subsidiary traits or measurements that are important but are not the end in them selves. (Sometimes referred to as a Reverse Fishbone)

Affinity diagram and  Fish bone diagram 1
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Originally posted 2012-08-26 06:58:00.

What is A3 thinking

A3 thinking- Definition

Forces consensus building; unifies culture around a simple, systematic methodology; also becomes a communication tool that follows a logical narrative and builds over years as organization learning; A3 = metric nomenclature for a paper size equal to 11”x17”

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Originally posted 2012-08-26 06:56:00.

Thinking of waste and avoidence of waste – some early thoughts

Continuing from the previous success of Arsenal of Venice in the great tradition of manufacturing there are some early thoughts into the lean and lean manufacturing. There are some early thoughts on avoidence of waste which have contributed greatly in their times.
The Great American Author, Scientist, philosopher, Benjamin Franklin has recorded in his poor Richards Almanac, about wasted time. He also mentioned about increasing profits by reducing costs He added that avoiding unnecessary costs could be more profitable than increasing sales: “A penny saved is two pence clear. A pin a-day is a groat a-year. Save and have.”. The same  thoughts continued in his book “The way to wealth”. Here he attacks carrying unnecessary inventory. here is the text  “You call them goods; but, if you do not take care, they will prove evils to some of you. You expect they will be sold cheap, and, perhaps, they maybe bought  for less than they cost; but, if you have no occasion for them, they must be dear to you”. Another statement form the same book “remember that many have been ruined by buying good penny Worth’s.”  If you look at these statements clearly, these were preaching avoidance of waste and the resulting profitability.
The concept further studied by Franklin Gilberth, who saw that some movements which are waste in the job of a mason. He Saw that the masons bend to pick the bricks and this takes considerable time. Gilberth came up with the scaffold, which reduced the movement and made the bricks available at a waist height. This has resulted in the speed of work.These are some clear early thoughts on eliminating the waste. These became foundation for the lean journey today. In fact, Henry Ford, who was one of the fore fathers of lean thinking got his inspiration form Benjamin Franklin.

The history of lean manufacturing continues. Next we will see the effect of industrial revolution which started around 1750 on the journey of lean.

I would request readers to add the history wherever possible.

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Originally posted 2012-08-19 12:38:00.

What is 5S and 6S

5S and 6S are the basic tools for organizing the workplace. They are the used for improving the work place culture. They are used organization of the workplace, the name comes from the six steps required to implement and the words (each starting with S) used to describe each step: sort, set in order, scrub, standardize, and sustain which are called as 5S and the Sixth S is added which is safety in the later stages
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Originally posted 2012-08-26 06:53:00.