Lean Lab Lexicon
Lean in the laboratory is a specialist area that is not always easy to understand, especially for beginners. Many terms originate from Japanese and are difficult to remember. There are also numerous abbreviations that need to be known to understand the various lean techniques.
To make it easy for you to look up these terms, we have compiled and explained the most important terms for the application of lean in the laboratory in this lean lab lexicon.
0-10
3M
The three M’s stand for terms that begin with M: Muda = waste, Mura = inflexibility and Muri= variability. The three terms are the three core issues that stand in the way of optimal fulfillment of customer needs.
5S
5S is one of the central lean tools. It is a methodology originally used in the production industry and increasingly in services, whereby the term stands for five steps, each beginning with an “S”. 5S is an instrument for organizing workplaces efficiently and at the same time safely and cleanly. Order and cleanliness are a basic prerequisite for safe and efficient processes.
5-Why
5-Why is a method for analyzing cause-and-effect relationships in order to increase the reliability of processes and reduce errors. The term stands for the “fivefold question” of “why” and aims to determine the cause of a fault or device defect. It is important to keep asking the question “why” until the root cause of the fault has been clearly identified.
7 types of waste
The concept of the 7 types of waste is one of the classic lean techniques. A distinction is made between 7 types of waste:
- Transportation
- Stocks
- Movement
- Wait
- Overproduction
- Overprocessing (“complex or complicated processes”)
- Reject/error
A
A3
The term A3 refers to a document template in DIN A3 format that is used to describe and subsequently optimize problems. In addition to illustrations and tables, an A3 also contains graphics to give those involved in solving a problem a quick overview of the key information and thus help them to quickly understand a problem and then work on solutions.
Andon
The term andon (Japanese andon = “paper lamp”) is a method of visual management to indicate the current operating status of a device or machine in an easily recognizable way. In its original form, different colored light signals are used to describe the current status.
B
Benchmarking
Benchmarking is a competitive analysis tool. It involves comparing products, services and the underlying processes with one or more companies or parts of companies on the basis of key figures and practices. The aim is to identify a so-called performance gap to the best company or a group of the best companies (e.g. the top 10% of the best companies) and to describe the processes and practices responsible for the performance gap in order to then improve them.
Order point
The order point is a stock of materials that triggers an order when it is reached. The stock is calculated from the safety stock (also known as the “iron reserve”) and the expected consumption during the period until the order is received.
Company suggestion scheme
The business suggestion scheme is an instrument for continuous improvement in companies. The suggestions or ideas for improvement come from one or more of the company’s employees. In order to motivate employees to submit suggestions, selected suggestions are rewarded (financially). The employee suggestion scheme is an integral part of idea management.
Bottleneck Analysis
C
Chaku-Chaku
The term chaku-chaku (Japanese for “loading, loading”) refers to a type of so-called “multi-machine handling”. This means that an employee operates several machines arranged close together, often in a U-shape. The employee is responsible for operating the machines and loading and unloading them with the materials (hence “loading” = chaku). After starting a process on a machine, it often performs a series of tasks without an employee having to watch the machine.
Change Agent
The term change agent describes a person who promotes and implements innovations and changes or innovations in the personal, organizational or economic-technological area in a transformation project, e.g. a lean transformation.
Critical Path Method
The critical path method originates from the field of network planning technology. The method helps to identify and control or optimize activities that can lead to an increase in the overall lead time and are therefore on the “critical path”.
D
Deming Circle
See PDCA cycle
Lead time
The lead time is the period of time that elapses in the production of a good or service between the start of the first work process and the completion of the last work process. The lead time of an order includes both the time in which productive activities take place and waiting times in which an intermediate service or product or order is not processed further.
E
Bottleneck analysis
The bottleneck analysis is based on Goldratt’s “Theory of Constraints (TOC)”. When a bottleneck occurs, e.g. of resources (employee time or equipment capacity), the constraint can be examined using this analysis. The aim is to increase throughput. This is typically done in several steps: Identify the bottleneck, fully utilize the bottleneck and then increase the capacity of the bottleneck.
F
FMEA - Failure Mode and Effects Analysis
FMEA – Failure Mode and Effects Analysis (FMEA) is an analytical method for increasing the reliability of processes and reducing errors. Possible product defects are evaluated according to their significance for the customer or for performance, their probability of occurrence and their probability of detection, each with a key figure. The aim of the method is to avoid errors from the outset instead of identifying and subsequently correcting them.
FIFO principle
The term FIFO is an abbreviation for first-in-first-out. It refers to a priority principle of queueing theory, according to which objects arriving first (e.g. materials, customers, products) are processed or served first. The principle is also applied in the valuation of inventory items in accordance with Section 256 HGB.
G
Gemba Walk
Gemba is a Japanese term that means “the actual place” or “the real place”. In Japan, police officers or reporters refer to the crime scene or the place of reporting as Gemba. In the Lean context, Gemba refers to the place where value is created. For example, at a machine in a factory, at a PC at the workplace. During a so-called Gemba Walk, i.e. an on-site tour, managers go to the place where value is created. The idea behind this is that problems can best be identified on site and solutions or optimization ideas can best be developed directly on site.
Genich Gembutsu
The term Gembutsu is a central principle in lean management. The basic idea is that you should not just rely on figures, data and opinions from others, but should also form your own picture of the situation on the ground and try to understand the reality as well as possible.
Overall equipment effectiveness
Overall equipment efficiency (OEE) is a key figure that is a measure of the added value of a system. This key figure can be used to show both the productivity of a system and the losses, e.g. in the form of a waterfall diagram (OEE diagram). The key figure shows the proportion of efficient production time in relation to the total occupancy time of a plant. It must be distinguished from capacity utilization.
H
Heikinka
The Japanese term “Heikinka” refers to a principle in which the actual irregular customer orders are decoupled from the production program to be produced by means of a so-called “leveling”. The aim of leveling is to smooth out demand. Kanban control is often used as part of leveling.
I
Ishikawa diagram
An Ishikawa diagram (also known as a fishbone diagram) is a graphical representation of causes that resembles a fishbone and helps to analyze quality problems. All influencing factors in the areas of man, machine, material, method and environment are included in the diagram. All possible causes of problems along these influencing factors are to be identified and then systematized.
K
Kaizen
The Japanese word “kaizen” refers to a process for the continuous improvement of product, process and service quality. In other words, it involves incremental “innovations” or improvements in “small steps”. It is often used synonymously with the term CIP (continuous improvement).
Kaikaku
Kaikaku is a Japanese term. It stands for radical or “disruptive” changes or “innovation” in a production organization or system. It represents the opposite of continuous improvement processes (kaizen).
Kanban
“Kanban” (Japanese) literally means “card”. In a Kanban system, Kanban cards are used to control a manufacturing process in a decentralized and flexible manner. It can be used to control intermediate stages of production as well as to control the materials required.
Capacity planning
Capacity planning is a concept for determining the output quantity. By comparing the current vs. the maximum output quantity, the capacity utilization of a company division can be determined. Capacity is a key control parameter for every manager with personnel responsibility.
Key figures
Key figures are numbers used to describe an operational situation. For example, a distinction is made between absolute and relative key figures or between inventory key figures and historical key figures. If key figures are compared across companies, this is referred to as “benchmarking”.
KPI (Key Performance Indicator)
The term key performance indicator (KPI) refers to a key figure that generally describes the performance of a process (process KPI) or end product in aggregated form. A distinction is made between different types of KPIs.
Continuous improvement process
A continuous improvement process (CIP) is a procedure for the continuous improvement of product, process and service quality. In other words, it involves incremental “innovations” or improvements in “small steps”. The Japanese word “kaizen” is often used synonymously for a permanent improvement process.
L
Laboratory planning
Laboratory planning is the planning of a new laboratory building or conversion (also known as refurbishment or modernization). The planning activities include planning the building architecture, planning the layout of the laboratory furniture and infrastructure and the supply technology (also referred to as building services or technical equipment (TGA)). Consequently, laboratory planning goes beyond pure technical planning.
Laboratory layout
A laboratory layout is a specific form of layout. The “objects” here are the laboratory equipment, laboratory furniture and infrastructure such as fume cupboards, sinks, etc. The creation of a laboratory layout is part of laboratory planning. If lean principles are incorporated when creating the layout, this is referred to as a lean lab design or lean lab layout. Such a layout not only takes into account the requirements of the laboratory technicians, but also optimizes the routes and processes so that laboratory activities can be carried out more efficiently, reliably and safely.
Layout
A layout is the spatial arrangement of “objects” within a company. Objects can be, for example, devices, machines, furniture or other equipment that are necessary for the provision of services. In a broader sense, layout also refers to the conception of rooms (macro layout), while in a narrower sense, it refers to the arrangement of objects within rooms. The process of creating a layout is part of the planning of a production building.
M
Makigami process illustration
The Makigami process diagram (also known as a swimlane diagram) is a lean technique that can be used to visualize, analyse and optimize business processes of all kinds. The technique is particularly suitable for multi-stage processes with several participants or areas involved.
Milkrun concept
The milk run concept is an internal material logistics concept for providing material in line with demand. The original concept is based on the basic idea that only the quantity of material that has been used is replenished. The batch size is defined once (e.g. a milk bottle) and controlled by cards (Kanban) if necessary. The replenishment cycle and the route are also defined in advance (comparable to a bus timetable). The person who carries out the replenishment is sometimes called the “milk runner”. The advantage of a milk run compared to the individual compilation of materials is that walking distances can be saved and the security of supply can be increased.
MIFA
Muda
The Japanese term muda stands for waste. See 7 types of waste.
Mura
The Japanese term mura (inflexibility) refers to the characteristic of a company or department that prevents a department from meeting the customer requirements of all or some of its customers. In other words, too little or too much service is provided in some cases, but not exactly the service that a customer requires.
Muri
The Japanese term muri (variability) refers to the deviation from planned parameters. In other words, it is about describing and improving the stability of process or performance parameters in order to make processes more robust. Six Sigma focuses on this perspective.
N
Nichijou Kanri
The Japanese term Nichijou Kanri describes daily management by independently led working groups.
Non Value Added
The term “non-value added” originates from the concept of “waste analysis” and describes an activity that increases costs without contributing to the added value of a product or process. Consequently, it does not add value.
O
One-Piece Flow
The term one-piece flow describes a flow production system in which a semi-autonomous team usually oversees an order or product from start to finish (sometimes until completion). This can be particularly helpful in the production of variants, as a team can concentrate on a specific order.
Overall Equipment Efficiency
The term “Overall Equipment Efficiency” (OEE) is a concept for measuring and optimizing overall equipment efficiency, i.e. the productivity of equipment compared to the productivity of employees (“Overall People Efficiency” = OPE).
P
PDCA cycle
The deming cycle (also known as the Deming wheel, Shewhart cycle or PDCA cycle) is an iterative three- or four-phase process for improving the process. PDCA stands for P=Plan, D=Do, C=Check, A=Act, which in German also translates as “Plan, Do, Check, Implement”.
Poka Yoke
Poka Yoke is a concept of continuous quality improvement through the avoidance of “accidental” errors. Such errors are caused, for example, by inattention or fatigue. By setting up (technical) aids such as sensors, the occurrence of errors is to be avoided or an error that has occurred is to be rectified immediately. The aim is to make a process more reliable (“foolproof”).
Pull principle
The pull principle is a concept for the material flow in a production system. The term is also known as the “pull principle”. A value-added stage is only supplied with raw materials or results from the preliminary stage when it actively requests or “pulls” them. The pull principle stands in contrast to the push principle. A Kanban system is based on the pull principle.
Push principle
The push principle is a material supply concept. The push principle means that the supply of materials is controlled by a central point. It ensures that materials (e.g. chemicals or consumables in the laboratory) are “pushed” or “pushed in” through the value creation steps according to a planned schedule, e.g. an expected consumption quantity.
Process mapping
Process mapping involves the recording of processes as well as their steps and times. The recording can primarily be done graphically (process visualization) or in tabular form. The recording of processes is a central step in the optimization of processes.
R
Set-up time reduction
Setup time reduction is a systematic procedure for reducing the setup times of a machine or device.
S
Sensei
The term sensei refers to an expert, teacher or coach. In the lean field, the term often overlaps with mentor.
Six Sigma
The term Six Sigma (6σ) refers to three things: (1) a management system for process improvement, (2) a statistical quality objective and (3) a quality management method. The core element is the analysis, improvement and control of processes using statistical techniques. The DMAIC methodology is also frequently used.
SMED - Single Minute Exchange of Dies
The term Single Minute Exchange of Dies (SMED) is a method for improving set-up times, which is sometimes also referred to as “Quick Change Over”.
Spaghetti analysis
The spaghetti analysis is a lean management tool that is used to visualize work processes and material flows. The aim of a spaghetti diagram is to graphically depict the waste types “transportation” and “movement” and to determine the causes of the movement.
Standardization
The term standardization refers to standardization according to certain patterns. Standardization serves to reduce inter-company complexity in order to save costs and time. Standardized materials and equipment also reduce procurement costs.
Standard Work
The term “standard work” refers to the idea that processes are precisely described and best practices are defined so that employees can perform reliably and more efficiently.
Supermarket
The term supermarket refers to a location along or near production facilities where materials are pre-sorted and prepared for transfer to employees. The so-called first-in-first-out principle is applied.
Swimlane diagram
T
Cycle time
The term cycle time refers to the time required for a single work step in so-called “cycle production”. The cycle times must be coordinated so that no bottlenecks occur.
Theory of Constraints
The Theory of Constraints is an approach based on the ideas of Eliyahu M. Goldratt, which emphasizes the elimination of bottlenecks in order to increase the overall throughput of production systems.
TPM - Total Productive Maintenance
The term Total Productive Maintenance (TPM) is a concept for optimizing the use and increasing the efficiency of production facilities. TPM includes plant maintenance and repair measures.
TQM - Total Quality Management
The term total quality management (TQM) refers to a focus on improving quality that encompasses all areas of an organization (company, institution, etc.). In other words, it is a holistic approach to the strategic and operational management of companies. TQM aims to achieve a quality standard that is very similar to the goal of Six Sigma.
TPS - Toyota Production System
The Toyota Production System (TPS) is a fundamental philosophy based on specific principles (Just-in-Time, Kaizen, Jidoka) and a special culture. The TPS represents the origin of lean management.
V
Value Stream
The term value stream refers to a section of a company’s procedures or processes that generates a service for an (internal or external) customer.
Value Stream Design
The term Value Stream Design (VSD) refers to the second process step of Value Stream Management, a business management tool in the area of process optimization. In this step, the “target state” of an improved material and information flow of the entire value stream (VSD vision) is designed.
Value Stream Mapping/Analysis
Value stream mapping (VSM) or value stream analysis (VSA), also known as material and information flow analysis (MIFA), is the first step in a lean method to visualize the current state of a process in the form of a clear diagram. The value stream analysis is the basis for the subsequent reduction of waste.
Visual management
Visual management is about presenting information about the goals, results and performance of a process or a team of people to an employee in a visual form. A “white board” or digital board or panel/television is often used for this purpose.
W
Adding value
The term “value-adding” refers to any activity that makes a product or service valuable from the customer’s perspective. Colloquially, an activity is value-adding if “the customer pays for it”.
Value stream
See Value Stream