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5 Rules of On-error Training

1. Ownership Rule – the person who first detects the problem is responsible for finding the root cause of the

Gemba

The King Looking out Onto the Land In the Hot Sun Where the Pigs are

Toyota Vocabulary

Everyone working together in a large room without partitions: Obeya. Posting project team information on the wall of a dedicated

Five Frogs

Five Frogs are sitting on a log. Four decide to hop off. How many frogs are left?* It doesn’t take

Refine, Simplify, and Strengthen

Why is it that most lean and six sigma transformations are so complicated? All too often organizational transformations are loaded

oops!

Larry Loucka

Larry is a Certified Supply Chain Professional, Lean Sigma Master Black Belt, Mentor, and Trainer. He has extensive industry experience

Fixed Repeating Schedule

Fixed Repeating Schedule (FRS) also known as Every product Every Interval (EPEI) is a production schedule which is ‘unchanging’ and

Checklist

Check out Annals of Medicine: The Checklist by Atul Gawande in the Dec. 10. 2007 edition of The New Yorker

3P – Production Preparation Process

3P Production Preparation Process is an advanced lean approach involving visual thinking, simulation, kaizen for quick Design For Manufacturability. 3P

Moonlighting, Moonshining, Skunksworks, Trystorming and 3P

Moonlighting – work a second job, usually after hours; “The medical student is moonlighting as a taxi driver”.

Demand Segmentation

Traditional Product Quantity (PQ) or ABC analysis fails to recognize that high volume may not be predictable and that low

Product Family Turnover Rate, Every Product Every Interval

Description and examples for calculation mixed model EPEI or Every Product Every Interval, also known as PFTR or Product Family

Muda in the Warehouse

Although created in the manufacturing environment of Toyota by Taiichi Ohno, the Seven Wastes can be found almost everywhere, if

50 things to free up warehouse space

Business is growing and running out of space in the warehouse. What to do before moving to a new facility

PowerPoint and other miscommunications

Recently read Edward R. Tufte’s The Cognitive Style of PowerPoint: Pitching Out Corrupts Within and initially dismissed his thesis as

Bow Wave

Keeping due dates straight in an MRP environment is a fundamental prerequisite. Plot a time series for the number of

Supply Shortage

What to do when there’s an industry-wide shortage? Long Tern Agreements & relationship intimacy (get in bed) Prepay for process

Where to start? The 5 Rules of Lean DNA

Standardize process and standardize work Zero ambiguity Flow the process Speak with data Develop leaders who are teachers

Hoshin X-Matrix

Over a few days or weeks we build the strategic deployment message by documenting our priorities and plans. This document

Hoshin Kanri

At long last we now have a number of recent readable guides for understanding and implementing policy deployment in your

Hansei

Hansei is a concept that Toyota uses as a practical improvement tool. Toyota actually conducts Hansei events, like Kaizen events,

Nemawashi

In Japanese culture Nemawashi is an informal process of quietly laying the foundation for some proposed change or project, by

Personal Plimsoll Line

Plimsoll Line (nautical) properly the International Load Line, a mark on the hull of a merchant ship to show the

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