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Japanese Lean Terms

Posted: Mon Sep 09, 2024 1:20 am
by admin
Poka-Yoke: Poka poke is a Japanese term that means Mistake Proofing or Error Proofing. Poka-yoke techniques help to prevent, detect, and correct the error/defects that occur in the manufacturing process.

Kaizen: The kaizen principle or objective is the continuous improvement in the product and process quality by eliminating waste and creating values.

Genchi Genbutsu:
is a Japanese term that translates to "go and see for yourself." By visiting the Gemba and observing work processes, it is possible to gain a deeper understanding of the situation and find the most effective solution. The idea behind Genchi Genbutsu is that the best way to understand a problem is to go to where it is happening and observe it directly.

Muda is the Japanese word for waste. It refers to any activity or process that does not add value to the customer, such as waiting, overproduction, excess inventory, defects, unused talent, etc. Muda is considered to be the root cause of inefficiencies in a manufacturing process, and reducing or eliminating Muda is a key goal of Lean manufacturing.

Mura refers to unevenness or inconsistencies in a manufacturing process, such as fluctuations in demand or production rates. Mura can lead to overproduction, excess inventory, and other forms of waste, and it is important to eliminate mura in order to achieve a smooth and consistent flow of work.

Muri refers to overburden or unnecessary effort, such as overworking employees or using equipment beyond its capabilities. Muri can lead to burnout, errors, and other problems, and it is important to eliminate muri in order to achieve a safe and sustainable manufacturing process.

Yokoten is a Japanese term that refers to the practice of spreading and sharing best practices and improvements across different parts of an organization. The goal of Yokoten is to leverage the collective knowledge and experience of the entire organization to drive improvement and achieve business objectives. By utilizing Yokoten, companies can gain a competitive advantage, as they can learn from each other's successes and failures and continuously improve their own processes.

Kanban
A system of visual signals used to manage the flow of materials and information within a production process. Kanban cards are used to signal when more parts or products are needed. The Kanban system helps to reduce waste and improve efficiency by ensuring that only what is needed is produced.

Chaku Chaku is a Japanese term that refers to a smooth and continuous material flow in a manufacturing process. The term "Chaku Chaku" comes from the Japanese words "Chaku" (to load) and "Chaku" (to unload), and it is used to describe a process that flows smoothly without any delays or interruptions. In some places, you would find the translation of this as "load-load."


Heijunka is the process of production leveling, aimed at reducing bottlenecks and inefficiencies by smoothing out production rates and volumes.

Mizusumashi refers to the role within Lean systems focused on replenishing materials and supplies, ensuring they are available when and where needed.

Nagara promotes the smooth, continuous flow of work, optimizing efficiency and minimizing delays.

Shojinka involves adjusting the number of workers to match the workload, ensuring flexible and efficient operations.



Gemba is a Japanese term that refers to the actual place where work is performed. By visiting the Gemba and observing work processes, it is possible to identify opportunities for improvement and implement changes that will make the work more efficient and effective. The idea behind Gemba is to go to the source of a problem and observe it directly to gain a deeper understanding of the situation and to find the most effective solution.