LEAN CHEAT SHEET – Key Concepts

Purpose of Lean: Understanding Value Long-Term Vision

VA Value added

NVA Non Value added (Waste)

BVA NVA but necessary

Before After Goals that Steady, sustained
Through reinforce approach using Results
Deliver Value Removing all
empowered Mapping the Value Stream improvement not standardized
to Customer wastes
workforce hard targets processes
Value Stream
End-to-end business process
Keywords which delivers a product or
Lean culture
service to a customer.
The recipient of the product or service
Customer
you produce.
Muda - 7 wastes – TIM WOOD

Any activity that transforms the Non-value added transport of

Value Transportation
product or service that the customer materials or work.
Added
is willing to pay for.
Extra finished goods, work-in-
Activity that consumes resources Inventory
Waste process or supplies.
without adding value (Muda).
Any unnecessary movement within
Sequence of phases creating value. Motion
Flow a work process.
Every interruption is a waste.
Time spent waiting rather than
Lean is about development, self- Waiting
Engaged working.
reliance and skill building.
Producing anything earlier or in
Over Production
greater quantities than needed. Visual Management
The goal is to improve
Processing beyond what the
Over Processing ▪ Makes problems visible and immediate
customer truly needs.
▪ Communicates current conditions.
Time, effort and materials used to ▪ Triggers correct response or action.
Defects ▪ Seeing is knowing.
repair defects.

Muri & Mura

Want to communicate a
Muri Overburden on people and equipment.
standard on a chart?
Draw a horizontal target line.
Mura Unevenness in production. Are you above or below?
LEAN CHEAT SHEET - Tools
Just in Time House of Lean Jidoka
✓ Reduces Muda. ✓ Detects problems and abnormal
✓ Simplifies processes and promotes up-time. conditions and stop the process if any.
✓ Makes the most of limited space and resources. ✓ Reduces Muda preventing defects.
✓ Increases quality of final product.

Continuous Flow Andon (Visual control in production line)

• Make one, Move one.
▪ Line stopped in order to rectify something.
• Single piece flow.
▪ Worker calls for help.
▪ Everything is fine.
Takt Time vs. Cycle Time
• Takt time is setting the pace of production to
customer demand Error Proofing (Poka-Yoke)
• Cycle time is the time required to complete 1 • Mechanism that helps avoiding mistakes
operation. and preventing defects.

Pull System Autonomation

• Controlling the flow by replacing only • Automation with a human touch.
what has been consumed. • Building intelligent controls into machinery or
processes that can detect defects, stop and
Supermarkets and Kanban alert people.
• Supermarkets reduce inventory by storing
and replenishing at the pace of
Standardizing Processes Total Productive Maintenance
• Machine operator trained to do day-to-day
production. The replenishment signal is a
maintenance.
Kanban. ✓ Stabilizes and removes uncertainty. • Understand the machinery and identify
✓ It’s the baseline for continuous improvement. problems before they impact production.
• JIT is an evolution that takes a lot of commitment ✓ Reduces Muda.
from everyone. As you progress challenges will • Jidoka is an enabler for problem solving. It
arise. See these problems as opportunities and 5S ( Sort, Set order, Shine, Standardize, Sustain ) stops the process before the “trail goes cold” to
work through them. • Workplace Organization allow effective root cause analysis.
• A clean, organized workplace is a respected and
efficient workplace.
Leveling & Sequencing (Heijunka) Kaizen
Standardized work
• Eliminates waste by consistently applying best
✓ Reduces Mura , Muri and Muda.
practices. Forms a baseline for future ✓ Engages organizational participation
✓ Enabler to create a stable FLOW.
improvement activities. ✓ Reduces Muda.
✓ Reduces changeover; increases flexibility.
✓ Creates quick, sustained results
3 Key steps for Std Work
• Takt Time: Available time / number of unit sold.
• Work Sequence: Operator work sequence from PDCA- Plan Do Check Act
beginning to end. • Iterative four-step management method for
• Std WIP (SWIP): Refers to the minimum work-in- the control of processes and products.
process needed to perform repetitive operations.

• Reducing variation in Product and Process • Most powerful but least used Lean tool. • Kaizen is continuous improvement
will lead to higher quality. • Should not be restrictive or limiting. through small Steps.
• Higher quality leads to higher efficiency. • Should be done by the people who do the work. • Do it better, make it better.
• Higher efficiency leads to lower costs.