Lean Manufacturing Systems

  1. The Pillars of the Toyota Production System
    1. Just-In-Time Production
      1. JIT Fundamentals
        1. Core Principles
          1. Producing Only What is Needed
            1. Right Quantity at Right Time
              1. Inventory Reduction Benefits
              2. Takt Time Management
                1. Definition and Calculation
                  1. Customer Demand Pacing
                    1. Takt Time Adjustment
                      1. Production Rhythm
                      2. Continuous Flow Implementation
                        1. Cell Design Principles
                          1. Layout Optimization
                            1. Chaku-Chaku Lines
                              1. U-Shaped Cell Configuration
                                1. Multi-Process Handling
                                2. Pull System Operations
                                  1. Kanban Systems
                                    1. Production Kanban
                                      1. Withdrawal Kanban
                                        1. Kanban Rules
                                          1. Card Management
                                          2. Supermarket Systems
                                            1. Buffer Stock Management
                                              1. Replenishment Triggers
                                                1. Inventory Control
                                                  1. Visual Management
                                              2. Jidoka (Autonomation)
                                                1. Jidoka Principles
                                                  1. Quality at Source
                                                    1. Automation with Human Touch
                                                      1. Operator Empowerment
                                                        1. Problem Detection
                                                        2. Stop-the-Line Authority
                                                          1. Abnormality Response
                                                            1. Problem Escalation
                                                              1. Root Cause Investigation
                                                                1. Immediate Countermeasures
                                                                2. Visual Control Systems
                                                                  1. Andon Systems
                                                                    1. Status Indicators
                                                                      1. Alert Mechanisms
                                                                        1. Escalation Procedures
                                                                          1. Response Protocols
                                                                          2. Visual Displays
                                                                            1. Performance Boards
                                                                              1. Problem Tracking
                                                                                1. Status Communication
                                                                              2. Error Prevention
                                                                                1. Poka-Yoke Implementation
                                                                                  1. Prevention Devices
                                                                                    1. Detection Devices
                                                                                      1. Design Principles
                                                                                        1. Application Examples
                                                                                        2. Quality Assurance
                                                                                          1. In-Process Inspection
                                                                                            1. Self-Check Systems
                                                                                              1. Successive Check
                                                                                            2. Human-Machine Separation
                                                                                              1. Operator Flexibility
                                                                                                1. Machine Autonomy
                                                                                                  1. Multi-Machine Operation
                                                                                                    1. Skill Development

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                                                                                                2. The Five Principles of Lean Thinking

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                                                                                                4. Key Lean Tools and Methodologies