TPS TOOLS

© Nigel Thurlow 2012 LEAN JIDOKA:

1) Andon - a visual control mechanism that displays the current state
of work (i.e. abnormal conditions, work instructions and job

PRODUCTION SYSTEM progress).

2) Fixed-Position Stop - the position on the assembly line where a

repeating process is completed. It is at these positions that the line
will stop should an abnormality not be corrected in time.

3) Line-Stop ("andon") Cord - a mechanism, usually a rope, that a

worker may pull to signal the need for assistance and which will stop
the line if it can not be resolved quickly.

Jidoka ...kaizen (improve system). Just in Time

4) Pokayoke - low cost, highly reliable devices that will stop
processes in order to prevent the production of defective parts.

The ability to stop a Having only what is

process by man or needed, only when it's
THE "PILLARS" machine in event of a needed and only where JUST IN TIME:
problem it's needed 1) Continuous Flow - deploying consecutive processes next to each
OF THE SYSTEM Tools: Tools:
to eliminate in-process inventory and increase production flexibility.

Andon Continuous Flow

Fixed-Position Stop Flexible Motivated Employees Heijunka
2) Heijunka - the leveling of volume and variety produced over time.
(level production)
Line-Stop Cord Kanban
Pokayoke Multi-skilled Staff 3) Kanban - A small card that provides instruction and request to
...maintain standards. Std In-Process Inv produce or request goods.
Takt Time
4) Multi-Skilled Staff - workers are able to perform a greater variety
of activities to increase flexibility and opportunity to improve
continuous flow.

5) Pull System - the system in which following processes draw from

preceding processes the required parts, when they are needed and
in the exact amount needed.

Consensus & Foundational Stability through... Plan / Do 6) Standard In-Process Inventory - identifying an appropriate level of
Nemawashi Check / Action inventory contained within the continuous flow system to achieve

Genchi Genbutsu
"Go See"
STANDARDIZATION (reflection) optimal effectiveness.

7) Takt Time - the time allotted for the completion of each process in
Process of establishing the repeatability and predictability of Man, Material, Method & Machine in Root Cause the production system.
work which when properly maintained forms the basis from which improvement can be made. Analysis
Visual Control

STANDARDIZATION:
1) Nemawashi & Consensus Building - assuring success through good
relationships and good communication
For the Customer For the Employee For the Company
DESIRED 1) Highest Quality 1) Work Satisfaction
2) Genchi Genbutsu - going and seeing first-hand a situation rather
than hearing second-hand
1) Market Flexibility
OUTCOMES 2) Lowest Cost 2) Job Security
2) Profit (= Sales Price - Cost) 3) Visual Control - mechanisms that demonstrate visually condition
3) Shortest Lead-time 3) Consistent Income
and status

4) Plan / Do / Check / Action - the process of setting a target,

performing an activity, evaluating the results and taking necessary
"Customer 1st" "Respect for Humanity" "Elimination of Waste (Muda)" countermeasure activity to issues before setting a new target and
FOUNDATIONAL ...by aiming for 100% creative effort ...in Man, Material, Method or Machine repeating the process.
... is the principle of considering the need and
GOALS desires of the customer when determining
...by providing development ...in areas of over-producing, waiting, 5) Problem Solving (Root Cause) - identifying a problem and
...by providing challenges conveyance, processing, inventory, pinpointing it to a specific and addressable root cause which can be
direction and strategy. countermeasured to prevent the problem from occurring again.
...by mutual trust with management motion, correction