Lean Management

4.

Core Lean Tools and Methodologies

4.1.

Value Stream Mapping (VSM)

4.1.1.

VSM Fundamentals

4.1.1.1.

Purpose and Objectives

4.1.1.2.

Scope Definition

4.1.1.3.

4.1.1.4.

Data Requirements

4.1.2.

Current State Mapping

4.1.2.1.

Process Observation

4.1.2.2.

Data Collection

4.1.2.3.

Mapping Symbols

4.1.2.4.

Information Flow

4.1.2.5.

4.1.2.6.

Timeline Development

4.1.3.

Analysis and Waste Identification

4.1.3.1.

Process Metrics

4.1.3.2.

Bottleneck Analysis

4.1.3.3.

Waste Quantification

4.1.3.4.

Improvement Opportunities

4.1.4.

Future State Design

4.1.4.1.

Improvement Prioritization

4.1.4.2.

4.1.4.3.

Process Redesign

4.1.4.4.

Implementation Planning

4.1.5.

Action Plan Development

4.1.5.1.

Project Planning

4.1.5.2.

Resource Allocation

4.1.5.3.

Timeline Creation

4.1.5.4.

Responsibility Assignment

4.2.

5S Workplace Organization

4.2.1.

4.2.1.1.

Philosophy and Benefits

4.2.1.2.

Implementation Approach

4.2.1.3.

Sustainability Factors

4.2.2.

4.2.2.1.

Item Classification

4.2.2.2.

Red Tag Process

4.2.2.3.

Disposal Methods

4.2.2.4.

Decision Criteria

4.2.3.

Seiton (Set in Order)

4.2.3.1.

Organization Principles

4.2.3.2.

Visual Management

4.2.3.3.

Location Designation

4.2.3.4.

Accessibility Optimization

4.2.4.

4.2.4.1.

Cleaning Standards

4.2.4.2.

Inspection Procedures

4.2.4.3.

Maintenance Integration

4.2.4.4.

Problem Identification

4.2.5.

Seiketsu (Standardize)

4.2.5.1.

Standard Development

4.2.5.2.

Documentation Methods

4.2.5.3.

Training Programs

4.2.5.4.

4.2.6.

Shitsuke (Sustain)

4.2.6.1.

Habit Formation

4.2.6.2.

Discipline Maintenance

4.2.6.3.

Continuous Training

4.2.6.4.

Performance Monitoring

4.3.

Kaizen: Continuous Improvement

4.3.1.

Kaizen Philosophy

4.3.1.1.

Improvement Mindset

4.3.1.2.

Employee Participation

4.3.1.3.

Small Step Approach

4.3.1.4.

Systematic Method

4.3.2.

4.3.2.1.

4.3.2.2.

4.3.2.3.

Facilitation Techniques

4.3.2.4.

Implementation Process

4.3.2.5.

Follow-up Activities

4.3.3.

4.3.3.1.

4.3.3.1.1.

Problem Definition

4.3.3.1.2.

Root Cause Analysis

4.3.3.1.3.

Solution Development

4.3.3.1.4.

Implementation Planning

4.3.3.2.

4.3.3.2.1.

Pilot Implementation

4.3.3.2.2.

Data Collection

4.3.3.2.3.

Process Monitoring

4.3.3.2.4.

Issue Resolution

4.3.3.3.

4.3.3.3.1.

Results Analysis

4.3.3.3.2.

Performance Measurement

4.3.3.3.3.

Success Evaluation

4.3.3.3.4.

Learning Capture

4.3.3.4.

4.3.3.4.1.

Standardization

4.3.3.4.2.

Training Update

4.3.3.4.3.

Horizontal Deployment

4.3.3.4.4.

Next Cycle Planning

4.3.4.

Gemba Management

4.3.4.1.

Gemba Walk Principles

4.3.4.2.

Observation Techniques

4.3.4.3.

Employee Engagement

4.3.4.4.

Problem Identification

4.3.4.5.

Coaching Opportunities

4.4.

Just-In-Time (JIT) Production

4.4.1.

4.4.1.1.

Demand-Pull Production

4.4.1.2.

Inventory Minimization

4.4.1.3.

Quality at Source

4.4.1.4.

Supplier Integration

4.4.2.

4.4.2.1.

Calculation Methods

4.4.2.2.

Application Techniques

4.4.2.3.

Workload Balancing

4.4.2.4.

Capacity Planning

4.4.3.

Flow Implementation

4.4.3.1.

4.4.3.2.

Layout Optimization

4.4.3.3.

Batch Size Reduction

4.4.3.4.

Setup Time Reduction

4.4.4.

Supplier Relationships

4.4.4.1.

Partnership Development

4.4.4.2.

Quality Agreements

4.4.4.3.

Delivery Scheduling

4.4.4.4.

Communication Systems

4.5.

4.5.1.

Kanban Fundamentals

4.5.1.1.

Visual Management Principles

4.5.1.2.

Signal-Based Control

4.5.1.3.

Pull System Implementation

4.5.1.4.

Flow Optimization

4.5.2.

4.5.2.1.

Production Kanban

4.5.2.2.

Withdrawal Kanban

4.5.2.3.

Supplier Kanban

4.5.2.4.

Emergency Kanban

4.5.3.

4.5.3.1.

Card Design Elements

4.5.3.2.

Information Requirements

4.5.3.3.

Quantity Determination

4.5.3.4.

Routing Instructions

4.5.4.

Work-in-Progress (WIP) Management

4.5.4.1.

WIP Limit Setting

4.5.4.2.

Bottleneck Management

4.5.4.3.

Flow Monitoring

4.5.4.4.

Capacity Balancing

4.5.5.

4.5.5.1.

Physical Board Design

4.5.5.2.

4.5.5.3.

Status Tracking

4.5.5.4.

Performance Metrics

4.6.

Jidoka: Autonomation

4.6.1.

Jidoka Principles

4.6.1.1.

Automation with Human Intelligence

4.6.1.2.

Quality at Source

4.6.1.3.

Problem Detection

4.6.1.4.

Immediate Response

4.6.2.

4.6.2.1.

4.6.2.2.

4.6.2.3.

Escalation Procedures

4.6.2.4.

Response Protocols

4.6.3.

Line Stop Authority

4.6.3.1.

Employee Empowerment

4.6.3.2.

4.6.3.3.

Problem Resolution

4.6.3.4.

Restart Procedures

4.6.4.

Human-Machine Separation

4.6.4.1.

Task Allocation

4.6.4.2.

Skill Requirements

4.6.4.3.

Safety Considerations

4.6.4.4.

Efficiency Optimization

4.7.

Poka-Yoke: Error-Proofing

4.7.1.

Error-Proofing Principles

4.7.1.1.

Mistake Prevention

4.7.1.2.

Detection Methods

4.7.1.3.

Correction Mechanisms

4.7.1.4.

Design Integration

4.7.2.

Poka-Yoke Types

4.7.2.1.

Control Methods

4.7.2.2.

Warning Methods

4.7.2.3.

Shutdown Methods

4.7.2.4.

Contact Methods

4.7.2.5.

Fixed-Value Methods

4.7.2.6.

Motion-Step Methods

4.7.3.

Implementation Process

4.7.3.1.

4.7.3.2.

Solution Design

4.7.3.3.

Testing and Validation

4.7.3.4.

Standardization

4.7.4.

Device Categories

4.7.4.1.

Mechanical Devices

4.7.4.2.

Electrical Systems

4.7.4.3.

Software Solutions

4.7.4.4.

Procedural Methods

4.8.

Heijunka: Production Leveling

4.8.1.

Leveling Principles

4.8.1.1.

Volume Smoothing

4.8.1.2.

4.8.1.3.

Resource Optimization

4.8.1.4.

Variation Reduction

4.8.2.

4.8.2.1.

Design Principles

4.8.2.2.

Scheduling Methods

4.8.2.3.

Visual Management

4.8.2.4.

Flexibility Maintenance

4.8.3.

Implementation Strategies

4.8.3.1.

Demand Analysis

4.8.3.2.

Capacity Planning

4.8.3.3.

Schedule Development

4.8.3.4.

Performance Monitoring

4.9.

Standardized Work

4.9.1.

Standardization Principles

4.9.1.1.

Best Practice Documentation

4.9.1.2.

Consistency Achievement

4.9.1.3.

Training Foundation

4.9.1.4.

Improvement Baseline

4.9.2.

Standard Work Elements

4.9.2.1.

Takt Time Integration

4.9.2.2.

Work Sequence Definition

4.9.2.3.

Standard Inventory Levels

4.9.2.4.

Quality Checkpoints

4.9.3.

Documentation Methods

4.9.3.1.

Work Instructions

4.9.3.2.

Visual Standards

4.9.3.3.

4.9.3.4.

Training Materials

4.9.4.

Maintenance and Improvement

4.9.4.1.

4.9.4.2.

Update Procedures

4.9.4.3.

Employee Feedback

4.9.4.4.

Continuous Enhancement

4.10.

Root Cause Analysis

4.10.1.

Problem-Solving Approach

4.10.1.1.

Systematic Investigation

4.10.1.2.

Data-Driven Analysis

4.10.1.3.

Team-Based Solutions

4.10.1.4.

Prevention Focus

4.10.2.

Five Whys Technique

4.10.2.1.

Question Formulation

4.10.2.2.

4.10.2.3.

Root Cause Identification

4.10.2.4.

Solution Development

4.10.3.

Fishbone Diagram

4.10.3.1.

Cause Categories

4.10.3.2.

Brainstorming Process

4.10.3.3.

Relationship Mapping

4.10.3.4.

Priority Setting

4.10.4.

Other Analysis Tools

4.10.4.1.

Pareto Analysis

4.10.4.2.

Scatter Diagrams

4.10.4.3.

4.10.4.4.

Histogram Analysis

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