B
1 term
Built-in Quality, Building in Quality
See: Jidoka.
Open full definition
Lean vocabulary: the dictionary for your organization's performance
Master the meaning of lean terms and concepts. Get clear definitions that turn the language of management into practical results in your day-to-day work.
Alphabetical navigation of the dictionary
C
5 terms
Cell
A location where the processing steps for a given item take place immediately one after another, so that parts, documents, etc. can move in a flow very close to continuous, whether one unit at a time or in small batches, maintained throughout the complete processing sequence.
See: Continuous Flow, Operator Balance Chart, Standardized Work.
Chaku-Chaku
A method of conducting one-piece flow in a cell in which the machines unload parts automatically, so that the operator (or operators) can carry a part directly from one machine to the next without stopping to unload it, thereby saving time and motion.
See : Cell, Continuous Flow.
Changeover
The process of switching production from one product to another on a machine (for example, a press or an injection molding machine) or on a series of linked machines (an assembly line or cell) by changing parts, dies, fixtures, molds, etc. (Also known as setup.) Changeover time is measured as the time elapsed between the last part of the run just completed and the first good part after the changeover.
See : Single-Minute Exchange of Die - SMED.
Continuous Flow
Producing and moving one item at a time (or a small batch of items) through a series of processing steps as continuously as possible, with each step making just what is requested by the next step.
See : One-Piece Flow, Batch and Queue, Flow Production.
Cycle Time
The time required to produce a part or complete a process, as actually measured.
Open full definition
E
1 term
Error-Proofing
Methods that help operators avoid mistakes in their work, such as choosing the wrong part, assembling a part incorrectly, forgetting a component, etc. Also known as poka-yoke (defect-proofing) or baka-yoke (foolproofing).
See : Inspection, Jidoka.
F
3 terms
Five S
Five related terms, all beginning with the letter S, that describe workplace practices useful for visual management and lean production. The five Japanese terms are: Seiri: Separate needed items from unneeded ones - tools, parts, materials, documents - and discard the latter.
Seiton: Arrange what remains, defining a place for everything and putting everything in its place.
Seiso: Cleaning.
Seiketsu: Standardization resulting from good performance in the first three Ss.
Shitsu
Fixed-Position Stop System
A method of dealing with problems on production lines by stopping the line at the end of the work cycle, that is, at a set position, if a problem is detected and cannot be solved within the work cycle.
See: Andon, Automatic Line Stop, Jidoka.
Flow Production
A production system introduced by Henry Ford at the Highland Park plant in Michigan in 1913. The aim of flow production was to drastically reduce product throughput time and human effort through a series of innovations. See : Continuous Flow.
Compare with : Mass Production.
L
2 terms
Labor Linearity
A philosophy for flexibly managing the amount of labor needed in a production process (particularly in a cell) so that the number of operators increases or decreases with production volume. See : Capital Linearity.
Open full definition
Lean Production/Lean Manufacturing
A business system for organizing and managing product development, operations, suppliers, and customer relations. Compared with mass production, lean production requires less human effort, less space, less capital, and less time to make products with fewer defects to precise customer desires. See : Toyota Production System.
Compare with : Mass Production.
M
3 terms
Multi-Machine Handling
A work practice in which operators run more than one machine in a layout of process islands. It requires separating human work from machine work and is normally made easier by applying jidoka and auto-eject devices on the machines.
See: Jidoka, Multi-Process Handling.
Multi-Process Handling
A work practice in which operators work on more than one process in a layout oriented to the flow of products. It requires training operators to handle different types of machines (e.g., cutter, polisher, tester, etc.) so that they can move products through the cellularized operations.
See: Multi-Machine Handling.
Muri
Overburdening equipment or operators by requiring them to run at a higher or harder pace, with more force or effort, for a longer period of time than they can withstand.
Open full definition
O
4 terms
Off-Cycle Work
Tasks in processes with many operators that require him or her to interrupt the work rhythm or leave the area.
See : Standardized Work.
One-Piece Flow
Making and moving one piece at a time. See : Continuous Flow, Every Product Every Interval (EPEx), Single-Minute Exchange of Die - SMED.
Open full definition
Operation
Work performed on an item by a machine or a person.
See: Process.
Operator Balance Chart
A graphical tool that helps create continuous flow in a multi-step, multi-operator process by distributing the operator's work elements in relation to takt time. Also known as an operator loading diagram or yamazumi board.
See: Yamazumi Board.
P
5 terms
Point-of-Use Storage
Storing parts and materials as close as possible to the operations that use them.
Open full definition
Poka-Yoke
See: Error-Proofing.
Open full definition
Process
A series of individual operations that must occur in a specific sequence to create a design, fulfill an order or make a product.
Open full definition
Process Capacity Sheet
See: Standardized Work.
Open full definition
Production Preparation Process
A disciplined method for designing a lean production process for a new product, or for fundamentally redesigning the production process for an existing product when the product or demand changes substantially. It may also be called Lean Process Development.
See: Kaizen, Kaizen Workshop.
R
1 term
Right-Sized Tools
Highly capable process equipment that is easy to maintain (and therefore available to produce whenever needed), allows quick changeovers, is easy to move and is designed to be installed in small increments of capacity, in order to facilitate labor and capital linearity.
See : Capital Linearity and Labor Linearity.
Compare with : Monuments.
S
4 terms
Setup Reduction
The process of reducing the time needed to change a process over from one model to another, from the last piece of the previous product to the first good piece of the next product.
See: Changeover, Single-Minute Exchange of Die (SMED).
Single-Minute Exchange of Die (SMED)
A process for changing production equipment over from one part to another in the shortest possible time. SMED refers to the goal of reducing changeover times to a single digit, or less than 10 minutes.
See : Changeovers, Setup Reduction, Shingo.
Standard Inventory
The amount of inventory needed before each processing step so that it flows smoothly. See: Inventory .
Open full definition
Standardized Work
Establishing precise procedures for the work of each operator in a production process, based on the following three elements: Takt time, which is the rate at which products must be produced to meet customer demand.
The exact work sequence in which an operator performs tasks within takt time.
The standard inventory, including items on the machines, required to keep the process operating smoothly.
See : Kaizen, Operator Balance Chart, PDCA, Takt Time.
T
3 terms
Takt Image
Creating awareness of takt time in areas of a production process where products cannot be delivered and withdrawn at the frequency of the takt time. See : Pitch, Takt Time.
Open full definition
Takt Time
Available production time divided by customer demand. For example, if a factory operates 480 minutes per day and customer demand is 240 units per day, takt time is two minutes. Similarly, if customers want two new products per month, takt time is two weeks. The purpose of takt time is to precisely match production with demand by providing a rhythm for the production system. It is the heartbeat of a lean system.
See: Cycle Time, Heijunka, Just-in-Time Production, Operator Balance Chart, Pacemaker Process, Pitch, Takt Image.
Total Productive Maintenance
A series of techniques pioneered by Denso (Toyota Group) in Japan to ensure that every machine in the production process was always able to perform its tasks. See : Overall Equipment Effectiveness (OEE).
Open full definition
W
1 term
Work
Human actions (movements) involved in making products. These actions can be divided into three categories: value creation, incidental work and waste.
Open full definition
Y
1 term
Yamazumi Chart
Yamazumi is the Japanese term for "pile" or "heap".
See : Operator Balance Chart.
Explore new formats in the knowledge center
Go beyond the introductory reading by listening to debates or watching our transformations on video.
Lean Institute Brasil podcast
Videos, webinars
and interviews
Books and publications
Knowledge center
Frequently asked questions about the Lean Glossary
It is a glossary of terms and concepts used in lean management. It helps you understand lean terminology by aligning definitions and examples for study, reading and day-to-day application.
Use the search box to look for a specific term, browse by letter or filter by theme. Click the item to see a summary and open the full definition.
Some terms may have translations in other languages. When a translation is not available, the site may show the Portuguese version as a reference.
Yes. New terms may be added and definitions may be revised to keep the content clear, consistent and evolving over time.
Ao longo do Vocabulário, você encontrará links para conceitos relacionados e conteúdos do Lean Institute Brasil, como artigos, materiais da Central do Conhecimento, livros e capacitações.
A academia lean do Lean Institute Brasil oferece trilhas de capacitação EaD e presenciais, incluindo o Programa Prático de Formação Lean (PPFL), que ensina a utilizar frameworks consolidados e a aplicá-los resolvendo problemas de negócio reais.
