4GI

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Across
  1. 2. documented step-by-step task instructions for consistency (3)
  2. 7. visual signal system controlling production and material flow
  3. 10. fixed route for regular material delivery (2)
  4. 16. unequal workload across production stations (2)
  5. 17. overburden on workers or equipment
  6. 18. workplace organization method sort, set, shine, standardize, sustain(ac.)
  7. 20. producing goods in groups or lots (2)
  8. 23. stored basic materials for production (2)
  9. 24. time to complete one production unit (2)
  10. 25. partially completed products in production system (3)
  11. 30. meeting needs without harming future resources
  12. 33. system minimizing waste and maximizing value (2)
  13. 35. unevenness or variability in processes
  14. 36. cause-and-effect diagram identifying problem sources fishbone
  15. 37. required production pace to meet customer demand (2)
  16. 39. visiting workplace to observe real processes (2)
  17. 41. continuous small improvements involving all employees
  18. 43. ratio of productive time to total available time (2)
  19. 44. producing only what is needed, when needed, minimal inventory (3)
  20. 49. grid evaluating risk by likelihood and impact (2)
  21. 51. tool board with outlines for easy identification (2)
  22. 52. U-shaped layout for flexible workflow (2)
  23. 53. visual diagram of material and information flow (3)
  24. 54. quality method reducing defects using statistical control (2)
  25. 55. total time from order to delivery (2)
  26. 60. producing items one at a time without batching (2)
  27. 64. scheduled maintenance to avoid breakdowns (2)
  28. 67. unnecessary movement of workers or machines (2)
  29. 71. study of waiting lines and service systems (2)
  30. 72. recognizing potential sources of harm (2)
  31. 73. visual representation of process steps (2)
  32. 75. designing work to fit human capabilities and reduce strain
  33. 77. repair after equipment failure occurs (2)
  34. 78. muda mura muri waste concepts (4)
Down
  1. 1. production based on forecast not actual demand (2)
  2. 3. achieving best performance under constraints
  3. 4. evaluating potential hazards and impacts (2)
  4. 5. production triggered by real customer demand (2)
  5. 6. production smoothing to reduce variability (2)
  6. 8. layout showing movement paths in workspace (2)
  7. 9. waste non-value-added activity
  8. 11. excess inventory beyond demand needs
  9. 12. equal distribution of tasks across workers or machines (2)
  10. 13. mistake-proofing device preventing human errors
  11. 14. designing systems to reduce risks and accidents (2)
  12. 15. flow of goods from supplier to customer (2)
  13. 19. Key Performance Indicator measuring performance success(ac.)
  14. 21. bar chart showing frequency distribution of data
  15. 22. method to identify the main cause of a problem (3)
  16. 26. rate at which inventory is used and replaced (2)
  17. 27. workplace organization method for efficiency and cleanliness(ac.)
  18. 28. timeline chart showing project tasks and durations (2)
  19. 29. defects overproduction waiting motion transport inventory overprocessing skills
  20. 31. uneven movement causing delays or idle time (2)
  21. 32. grouping machines for efficient flow of similar products (2)
  22. 34. OEE measure of availability performance quality (3)
  23. 38. focusing on system constraint to improve flow (3)
  24. 40. Return On Investment profit relative to cost(ac.)
  25. 42. marking unnecessary items for removal (2)
  26. 45. equalizing work across production line stations (2)
  27. 46. National Institute for Occupational Safety and Health(ac.)
  28. 47. ongoing effort to enhance processes (2)
  29. 48. direct transfer from inbound to outbound transport (2)
  30. 50. Single-Minute Exchange of Die fast changeover technique (ac.)
  31. 56. 80/20 rule focusing on major causes of problems
  32. 57. late product delivery beyond planned schedule (2)
  33. 58. major equipment losses reducing OEE (2)
  34. 59. percentage of faulty products in production (2)
  35. 61. automation with human intelligence stops when defect occurs
  36. 62. signal card authorizing production or movement (2)
  37. 63. operator loads machines in sequence self-running process (3)
  38. 65. identifying slowest point limiting system capacity
  39. 66. execution of a plan or process in practice
  40. 68. First-In-First-Out material flow system (ac.)
  41. 69. iterative questioning technique to find root cause (2)
  42. 70. output achieved relative to input used
  43. 74. Define Measure Analyze Improve Control process improvement (ac.)
  44. 76. Plan Do Check Act continuous improvement loop (ac.)