In Chapter 3, I discuss the importance of communication in a lean organization. Lean manufacturing is a journey, so there must be ongoing information and training on lean principles and the importance of lean manufacturing to the company. To enhance communication about the program, you can use the information in this appendix to create your own poster and display it throughout the company.
Overproduction: Building the wrong items, at the wrong time, in the wrong quantity, and in the wrong order
Overprocessing: Redundant effort or too many checks
Transportation: Excessive movement of items
Motion: Excessive reaching, stepping, and walking in and out of the workstation
Waiting: Time period when manufacturing processes are out of synchronization
Inventory: Too many parts or partially built products and too many finished goods
Defects or rejects: Quality errors that require rework and added cost
A company kaizen program is an essential policy for lean implementation. Following are the key elements of a kaizen continuous improvement program:
Kaizen champion
Kaizen events
Kaizen steering committee
Kaizen event tracking and scheduling
Kaizen event communication
Monthly kaizen meeting