OPERATIONAL EXCELLENCE

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Across
  1. 1. A signaling device that gives instruction for production or conveyance of items in a pull system
  2. 8. Terms beginning with 'S' utilized to create a workplace suited for visual control and lean production.
  3. 10. A mistake proofing device or procedure to prevent a defect during order-taking or manufacture
  4. 11. The rate of customer demand. How often the customer requires one finished item.
  5. 12. The act of leveling the variety and/or volume of items produced at a process over a period of time.
  6. 13. A controlled inventory of items that is used to schedule production at an upstream process
  7. 15. When a piece of equipment has to stop producing in order to be fitted for producing a different item.
  8. 17. Ford recognized that, ideally, production should flow continuously all the way from raw material to the customer and envisioned realizing that ideal through a production system that acted as one long conveyor
  9. 18. Means that items are produced and moved from one processing step to the next one piece-at-a-time.
  10. 21. Time during which a machine is in operation
  11. 22. The time a product spends waiting in line for the next processing step
  12. 23. Continuously improving in incremental steps
  13. 25. A visual control device in a production area, giving the current status of the production system and alerting team members to emerging problems
  14. 26. The time required for one piece to move all the way through a process or value stream, from start to finish..
  15. 29. Operating a true continuous flow on machines and workstations placed close together in the order of processing, sometimes in a "U" shape
  16. 30. How frequently an item or product actually is completed by a process, as timed by direct observation.
  17. 31. The detailed choreographed patterns of movements practised either solo or in pairs.
Down
  1. 1. Radical improvement of an activity to eliminate waste, also called breakthrough kaizen, flow kaizen, and system kaizen.
  2. 2. A method of conducting single-piece flow in which the operators proceeds from machine to machine, Literally means "load-load" in Japanese
  3. 3. Any inventory between raw material and finished goods
  4. 4. Producing or conveying only the items that are needed by the next process when they are needed and in the quantity needed
  5. 5. Single minute exchange of dies
  6. 6. When each and every associate can see the flow of value to the customer, and fix that flow before it breaks down
  7. 7. Producing more, sooner or faster than is required by the next process
  8. 9. A precise description of each work activity specifying cycle time, takt time, the work sequence of specific tasks, and the minimum inventory of parts on hand needed to conduct the activity
  9. 14. The complete elimination of muda so that all activities along a value stream create value.
  10. 16. Japanese term meaning "the real place
  11. 19. Material produced by one process is used up in the same order by the next process
  12. 20. Creating more value for customers with fewer resources.
  13. 24. Any activity that consumes resources but creates no value for the customer
  14. 27. A product or service's capability provided to a customer at the right time, at an appropriate price, as defined in each case by the customer
  15. 28. Transferring human intelligence to automated machinery so machines are able to detect the production of a single defective part and immediately stop themselves while asking for help