Manufacturing Systems

The act of changing a line or machine from making one product to making another is called changeover. Changeover is when we switch from making one product (product A) to making a different product (product B). This involves getting the machines ready and getting everything prepared for the new process. It is considered a waste of time because you are not using the machine at that time, which means you are not producing anything. Additionally, you are still paying the operators and workers even though they are not being productive during that time. When automobile companies need to make new ...

The real purpose of 5S is more than just cleaning up once. The 5S method helps to make standards that show problems, keep things stable so we can make small improvements, reduce waste, make a focused and organized workplace, and work together to keep getting better. Visual Thinking describes the 5S system as creating a work environment that is easy to understand, organized, and always getting better.

Step into tomorrow with "Wired World." This captivating eBook is your vital guide to understanding and mastering the game-changing technologies that are transforming our lives Artificial Intelligence (AI) and the Internet of Things (IoT). In the opening chapter, you will be introduced to the basic principles of AI and IoT, setting a solid groundwork for the deep dive episodes that will follow. This is not just a theoretical journey; "Wired World" propels you directly into the heart of these technologies, exploring their profound connections and synergies. Witness how AI and IoT converge to ...

Production kanban, which translates to "sign" or "signboard" in Japanese, instructs an upstream process on the kind and number of goods to produce for a downstream process. In a pull system, a kanban is a signalling tool that provides approval and instructions for the manufacture or withdrawal (conveyance) of products. The conveyance used by the downstream process is referred to as the "withdrawal." The assembly process and the client, the assembly process and the supplier process, and the supplier process and the vendor all benefit from kanban. The Toyota production system is founded on ...

Andon is a system that alerts people to problems before they happen, in order to make the process more efficient and prevent issues. In manufacturing, an andon is a system that tells managers, maintenance workers, and other employees about a problem with quality or the manufacturing process. But is this all that Andon being?Andon is a system that alerts people to problems before they happen, in order to make the process more efficient and prevent issues. In manufacturing, an andon is a system that tells managers, maintenance workers, and other employees about a problem with quality or the ...

Takt is a German word that means the speed or rhythm of something. Takt time is a number that helps make sure that the pace of making pacemakers matches the pace of selling them. One of the most important things to consider in lean manufacturing is takt time. This is the rate at which customers want a certain group of products to be produced by one step in the manufacturing process. Takt time is a number that tells us how much time we have to make each item that the customer wants. Takt time is the time available for manufacturing divided by the number of orders. In the 1930s, the German ...

Using lean metrics in non-manufacturing processes can help make things work better and make customers happier. The ideas of lean thinking, like finding what's valuable, getting rid of waste, and always trying to get better, work for all kinds of businesses. This book has lots of examples to show how lean principles can be used in non-manufacturing areas like healthcare, accounting, and maintenance.

Pull production starts where most systems end — with the customer. Unlike traditional production where products are pushed into the market hoping someone will buy, pull production begins by listening to what is actually needed — how much, when, and where. In this clear and practical guide, Dr. Mohamed H. Soliman explains how pull systems work, how they reduce overproduction, and how they connect to Just-in-Time (JIT) as part of Toyota’s lean philosophy. You’ll learn: How downstream steps signal upstream steps for what is needed Why pull is the opposite of "make-to-stock" thinking ...

What if your machines could detect problems, stop themselves, and protect product quality — without constant supervision? That’s the power of Jidoka. In this concise, practical book, Dr. Mohamed H. Soliman explores how Jidoka, one of the two core pillars of the Toyota Production System, enables smarter operations by combining automation with human judgment. You’ll learn how Jidoka helps organizations: Build quality into every process Detect errors at the source and respond immediately Reduce waste and rework Free up operators to manage multiple machines (multiprocess handling) Create ...

How do you build reliable operations without killing innovation? The biggest challenge in implementing Standard Work is finding the right balance: Between giving employees clear, repeatable standards — and giving them space to think, improve, and grow. In this practical guide, Dr. Mohamed H. Soliman shows you how Toyota achieves that balance. You'll learn: Why most companies misunderstand Standard Work How to write effective standards that empower, not restrict Who should be involved in creating standards How Standard Work supports quality, cost, and delivery performance How it forms the ...

Many kaizen programs aim to have a continuous flow, which means processes are constantly moving without interruptions. This is also the ultimate goal of lean production. A "cell" is a group of devices that perform tasks in a certain order, but it is not often to find a smooth and uninterrupted process, which is what makes a cell. In an ideal world, the product would flow smoothly from the beginning to the end, reaching the customer through all the stages of its production. But that would be too much to handle all at once. We need a place where we can focus. That place uses a system called a...

Why do so many Lean implementations fail to deliver stable flow? Because they ignore the core secret behind Just-in-Time: Heijunka. In this concise, practical guide, Dr. Mohamed H. Soliman explains how production leveling — or Heijunka — helps organizations: Build predictable and stable production schedules Reduce overburden, bottlenecks, and downtime Align suppliers and internal processes for smoother flow Cut inventory without risking stockouts Unlock the full potential of Just-in-Time (JIT) systems Whether you're managing a factory floor or improving service operations, Heijunka is ...

Poka-yoke is a Japanese word that means "error-proofing". It involves using simple and cheap tools to help workers avoid making mistakes in their work. These devices prevent errors like using the wrong parts, forgetting to put in a part, or installing a part the wrong way. In simpler words, in Japanese, "poka" means making a mistake by accident, and "yoke" means stopping or avoiding the mistake. Have you ever wondered why Japanese cars are known for being reliable. Even cars that are 20 years old can still run well and keep up with the newest and top cars in the automobile industry. This is...

In recent years, financial professionals have been using outdated ideas and methods to judge how well companies are doing and give feedback to the bosses. This helps the executives and CEOs figure out what changes they need to make and make important choices. The boss wants assistance in locating the means to finance a new project. He wants to find areas where we can reduce costs in our products and services, as well as determine if changes made have led to making more money. The CEO wants assistance in understanding how the company has gotten better or worse and what the future will be ...

Toyota Motor Corporation made a system to make good products, save money, and make things faster by using less waste. TPS has two main parts, just-in-time and jidoka. It is often shown as a "house" image. To improve TPS and keep it running well, we use a process called PDCA or the scientific method. We do this by doing the same tasks over and over again and making small improvements called kaizen. TPS was created by Taiichi Ohno, who managed production at Toyota after World War II. Ohno began using TPS at Toyota in the 1950s and 1960s, starting with machining work. Then, he started using it...

Heijunka (Japanese for "production smoothing or leveling"): It is a technique used to smooth out production in all departments as well as that of the supplier over time in order to facilitate Just-In-Time (JIT) production. It means production leveling (finding and maintaining average production volumes). The fundamental goal of using the Heijunka technique is to supply goods at a steady rate so that upstream and downstream operations can likewise run at a steady and predictable rate, hence lowering the inventory. The heijunka technique works by leveling both the production volume and the ...

Yes, people called the Toyota Production System an inventory reduction program when they first heard of it. “Just in time” is one of the main pillars in the TPS. “Just in time” ideally means “one-piece flow.” Inventory is the greatest waste in the process, and it hides many problems, such as quality problems, breakdown times, waiting waste, and more. Let’s get back to history. Prior to the 1970 oil crisis, very few people in the world know what Toyota was up to. The fact that it emerged stronger than ever while many of its competitors were quite battered made people take ...

Dive into the intricate fabric of economic ecosystems with 'Economic Ecosystems: Exploring Industries and Sectors.' This comprehensive guide takes readers on a journey through the diverse landscapes of industries and sectors that drive global economies. This book delves into the historical roots, evolution, challenges, and innovations shaping each sector. With insightful analysis and engaging narratives, it offers a deep understanding of how these industries intersect, influence, and shape the world we live in. 'Economic Ecosystems' provides a captivating exploration of the interconnected ...