415
Glossary
advanced quality planning: a structured method of dening and
establishing the required steps necessary to assure that a product
satises the customer. Advanced quality planning embodies the
concepts of defect prevention and continuous improvement as con-
trasted with defect detection.
andons: special lamps that illuminate problems in the factory. Paging andons
are lists to request parts supplies; emergency andons alert super-
visors to abnormalities on the line; operation andons indicate the
machines’ current operation rates; progress andons help us monitor
the progress of line operations (Hirano 2009).
angle plate: a precise measurement device used to establish an accurate
90°vertical surface.
angularity: a three-dimensional geometric tolerance that controls how much
a surface, axis, or plane can deviate from the angle described in the
design specications.
ASME: The American Society of Mechanical Engineers. ASME is an orga-
nization that publishes technical materials and sets industrial and
manufacturing standards.
attitude surveys: production system measurable. Surveys measure how
employee attitudes help guide Ford production system (FPS) efforts
toward 90% employee satisfaction.
bonus tolerance: additional tolerance that applies to a feature as its size shifts
from a stated material condition. Both maximum material condition
(MMC) and least material condition (LMC) allow bonus tolerance.
build-to-schedule (BTS): production system measurable. BTS is the percent-
age of units scheduled for a given day that are produced on the cor-
rect day and in the correct sequence. BTS reects a plant’s ability to
produce what customers want, when they want it. BTS= Volume
Performance × Mix Performance ×Sequence Performance.
buzz-squeak-rattle (BSR): objectionable vehicle attributes in any product
especially in the automotive domain. All BSR issues are tracked by
engineering development and subsequently assigned to the most
responsible party for resolution, that is, engineering, manufactur-
ing, or the supplier. Although somewhat subjective, BSR issues
should be eliminated to achieve customer satisfaction.
capability study: a statistical analysis of the output from a machine or a pro-
cess to determine its capability. This analysis is especially important
when a new product is introduced so product quality and variation
reduction can be assessed.
416 Glossary
CATIA: a computer-aided three-dimensional interactive applications design
and manufacturing system. This software was developed and is
maintained by Dassault Systemes of France and is marketed in the
United States by IBM. It is known as a CAD/CAM system.
cellular manufacturing: a production approach that uses groupings of
manufacturing equipment, tools, and people organized to perform
an entire sequence of manufacturing operations in one contiguous
physical location (cell) (Duncan 1995).
changeover: the installation of a new type of tool in a metal working machine,
a different paint in a painting system, a new plastic resin and/or a
new mold in an injection molding machine, new software in a com-
puter, and so on. The term applies whenever a production device
is assigned to perform a different operation. Changeovers directly
impact the availability of equipment. Whenever a machine goes
down for changeover, it is unavailable for production. Improving
changeover time increases equipment availability. See also quick
changeover.
changeover reductions: the eight steps in the classic changeover improvement
process are (1) distinguish between internal and external activities;
(2) analyze what is being done in the changeover process; (3) list
ideas for shifting internal elements to external changeover; (4) list
ideas for streamlining internal activities; (5) list ideas for stream-
lining external activities; (6) prioritize and select ideas to test and
adopt; (7) plan next changeover using new ideas; and (8) document
procedure on a QPS sheet.
changeover time: time between the last good piece off one production run
and the rst good piece off the next run.
characteristic: a unique feature of a product or process, or its output, from
which variable or attribute data can be collected.
circular runout: a two-dimensional geometric tolerance that controls the
form, orientation, and location of multiple cross-sections of a cylin-
drical part as it rotates (ASME 2009).
circularity: a two-dimensional geometric tolerance that controls how much
a feature can deviate from a perfect circle (ASME 2009).
compliance report random audit: an audit performed during a process sign-
off (PSO) on-site visit to determine whether arbitrarily selected char-
acteristics of a part or process meet their specication requirements.
The part or process samples should be randomly selected.
concentric: sharing the same center.
concentricity: a three-dimensional geometric tolerance that controls how
much the median points of multiple diameters may deviate from the
specied datum axis (ASME 2009).
constraint: the operation that is preventing the plant’s capacity from
increasing.
417Glossary
continual improvement: the improvement of products, processes, and/
or services on an ongoing basis. The gains made through continu-
ous improvement activities are generally incremental, small-step
improvements, as contrasted with more dramatic and sweeping
improvements typically associated with initiatives such as policy
deployment. In Japan, the continual improvement process is often
called Kaizen (Duncan 1995).
continuing conformance tests (CCT): tests and evaluations performed dur-
ing production to monitor the effects of processing and to assure
continued conformance to engineering requirements.
control part: a single part which follows the manufacturing process from
beginning to end. Ideally, the control part is an important part of the
end product.
control plans: written descriptions of the systems for controlling parts and
processes. They are written by suppliers to address the important
characteristics and engineering requirements of the product. Each
part will have a control plan, but in many cases, family control plans
can cover a number of parts produced using a common process.
Customer approval of control plans may be required prior to pro-
duction part submission. Control plans must be linked to process
failure mode and effect analysis (PFMEA) and process ow chart.
coordinate tolerancing: a system for describing the design of a part that
compares its features to distances along three linear axes. These axes
create an imaginary rectangular grid.
COVISINT: a web-based system that grants qualied supplier users access
to selected portions of the DaimlerChrysler, Ford, and GM networks.
cross-section: a section of a feature that is formed by an intersecting imagi-
nary plane.
cycle time: (1) the time required to complete one cycle of an operation. If
cycle time for every operation in a complete process can be reduced
to equal target time, products can be made in single-piece ow.
(2) In cycle reduction activities, the elapsed time of a process from
beginning to end. This elapsed time includes both value-added and
non-value-added activity. In machine operations, cycle time is more
accurately dened as the time required for the machine to cycle
through one recurring sequence of activities (Duncan 1995).
cylindricity: a three-dimensional geometric tolerance that controls how
much a feature can deviate from a perfect cylinder.
datum: a point of reference. An imaginary, perfect geometric shape or form.
A perfect point, line, at plane, circle, and cylinder are all examples
of possible datums.
datum feature: a physical feature that acts as an acceptable substitute for a
datum. Datum features relate the various features of the part to each
other.
418 Glossary
datum reference frame: three imaginary planes perpendicular to one
another that are mapped onto the part to relate features to each other.
defect: a product/part that deviates from specications or does not meet
internal/external customer expectations. All defects are created by
errors.
design failure mode and effects analysis (DFMEA): a formalized method
for quantifying the risk associated with identied potential design
failure modes. It is used to identify corrective actions required to
prevent failures from reaching the customer. The DFMEA is a liv-
ing document that will be updated as the design changes and
progresses through design verication and production. The rst
iteration should be done before program release.
design of experiments (DOE): a statistical approach to efciently plan and
structure a series of controlled tests. In its broadest sense, it encom-
passes planning, setting up, and running the tests, and analyzing
the data. The goal is to identify the sources of product variation that
should be optimized or avoided for consistent product performance
with a minimum number of tests.
design verication plan and report (DVP&R): a formalized test plan-
ning and reporting tool. It itemizes all testing necessary to assure
that functional and reliability criteria and target requirements
are dened in specic measurable terms. It provides a convenient
reporting format for engineering development (ED), design verica-
tion (DV), production validation (PV) and continuing conformance
testing (CCT).
design verication tests (DV): demonstrates that the nal released compo-
nent or assembly meets design intent. The tests, sample sizes, and
performance requirements are detailed in engineering performance
standards.
dock to dock (DTD): a Lean and production system measurable. DTD mea-
sures the elapsed time between the unloading of material and the
release of nished goods for shipment. Using tools like visual fac-
tory and error proong improves DTD by moving material through
the system efciently. DTD=Total Number of Units of the Control
Part /End of Line Rate.
engineering change level, DCL: The drawing change level (DCL) is the lat-
est design level of the released drawing.
engineering change level, PCL: The part change level (PCL) is the latest
design level of the part (not necessarily the drawing).
engineering standards: written requirements that describe materials, pro-
cesses, performance, reliability, quality, and/or design requirements
for a material, process, or part, or a family of materials, parts, or
systems.
equipment availability: affected by equipment failure, changeovers, idling/
short stops, reduced speed, process defects, and reduced yield.
419Glossary
error: (1) any deviation from a specied manufacturing process. Errors
can be made by machines or people and can be caused by previ-
ous errors that have occurred. While an error may not produce a
defect, all defects are created by errors. When errors are eliminated,
defects will not be created. (2) Act or instance of deviation from
unexpected procedures or methods of work that results in defects,
scrap, rework, waste, injuries, or any non-value-adding natural con-
sequence (Duncan 1995).
error and mistake proong: Error proong is a method used to identify
potential process errors and either design them out of the product
or process or eliminate the possibility that the error could produce
a defect. Mistake proong is an approach used to develop methods
to clearly identify errors that may occur and prevent them from
becoming nonconformances.
error proong: a group-based improvement strategy that is targeted at elim-
inating defects, errors, and equipment abnormalities in production
processes before they occur. Error proong is part of in-station pro-
cess control. Using error-proong techniques to stabilize equipment
positively impacts measurables. For instance, error proong reduces
scrap, reruns, retests, and returns. Error proong improves rst time
through and customer satisfaction.
error-proong device: simple and inexpensive methods used to prevent
errors about to occur, or detect errors that have already occurred.
Some examples of error-proong devices are guide or reference
rod, template, limit or microswitch, counter, odd-part-out method,
sequence restriction, standardization, critical condition detector,
delivery chute, stopper/gate, and sensors.
error-proong steps: to do an effective error proong, the following steps
should be taken:
1. Identify and describe the defect
2. Determine where the defect is made/discovered
3. Detail the current standard procedure
4. Identify deviations from standard
5. Identify the red ag conditions where the defect occurs
6. Identify the type of error-proong device required to prevent the
error or defect
7. Create devices and tests for effectiveness
extended enterprise™: a DaimlerChrysler coordinated process that unies
and extends the business relationships of suppliers and sup-
plier tiers to maximize the effectiveness of vehicle development,
minimize total system costs, and improve quality and customer
acceptance.
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