Glossary of Terms

A visual management tool that signals problems in a process, allowing for immediate attention.

Example: Like a student raising their hand in class when they need help, an Andon light tells workers when a machine needs attention.

A standard or point of reference used to measure performance against.

Example: If you're running a lemonade stand, comparing your sales to the most successful stand in the neighborhood is benchmarking. 

Points in a process that limit the overall flow and speed of operations.

Example: When only one checkout counter is open at the grocery store, it becomes a bottleneck as everyone must wait in that single line. 

A method in pull systems where cards (Kanban) signal the need to produce or move materials.

Example: Like deli tickets indicating it's your turn, Kanban cards signal when to make or move items. 

Churn Rate: The percentage of customers who stop using a product or service in a given period.

Example: A software company loses 20 out of 100 subscribers in a month, resulting in a 20% monthly churn rate.

Measurable values that can take any number within a range.

Statistical tools that track process performance over time to detect unusual variations.

Example: Like tracking your daily homework time on a graph to see if some days take much longer than usual. 

(Cost of Poor Quality) Total cost is associated with preventing, identifying, and addressing quality issues.

Example: For a smartphone manufacturer, COPQ includes quality control, warranty repairs, and lost sales due to defects. 

(Critical to Quality) The key features that make customers happy with a product or service.

Example: For a bicycle, having working brakes is critical to quality - it must be safe to ride. 

Time to complete one unit of work from start to finish.

Example: In a coffee shop, cycle time is measured from order placement to drink delivery. 

Making decisions based on data analysis and interpretation rather than intuition.

Example: Like using test scores to decide which subjects to study more for an exam.

Countable, distinct values with gaps between them.

A problem-solving method using Define, Measure, Analyze, Improve, and Control steps.

Example: Like following a recipe - you plan, gather ingredients, figure out what's missing, make it better, and keep it good. 

Designing workspaces and tasks to fit the person doing them safely and comfortably.

Example: Adjusting your school desk and chair height so you can write without hurting your back.

(Enterprise Resource Planning) A computer system that helps manage all parts of a business.

Example: Like having one big digital notebook that keeps track of everything in your lemonade stand. 

(a component of COPQ) Problems found after a product reaches customers.

Example: Finding out your toy breaks right after buying it.

A method of leveling production by distributing work evenly to reduce waste and improve efficiency.

Example: Like spreading homework assignments evenly throughout the week instead of cramming them all in one day.

A statistical method used to determine if there is enough evidence to support a specific claim about a data set.

Example: Like testing if a new study method really improves your grades compared to the old one.

The branch of engineering focused on optimizing complex processes, systems, or organizations. It also designs, improves, and implements integrated systems of people, materials, and equipment.

Example: Like organizing a school event by efficiently coordinating volunteers, supplies, and activities.

(a component of COPQ) Problems caught before products reach customers.

Example: Finding a broken cookie in the batch and removing it before selling. 

(Internet of Things) A smart device that connects to the internet to share data.

Example: A thermostat that you can control with your phone. 

Automatically stopping work when problems occur to prevent defects.

Example: Like a washing machine stopping if the lid opens.

(Just-in-Time) Making or delivering things exactly when needed.

Example: Making sandwiches only after customers order them.

Visual signal system to control workflow.

Example: Using sticky notes on a board to show what homework needs doing. 

A visual workflow management method that signals when to produce or move items.

Example: Like using sticky notes on a board to show which homework assignments are done, in progress, or need to be started.

Total time from order to delivery.

Example: Time between ordering a pizza and it arrives at your house. 

(Manufacturing Execution System) Computer system tracking production in real time.

Example: Like a scoreboard showing how many cookies each baker makes.

A manufacturing technique where products are built from interchangeable parts or modules.

Example: Like building a LEGO set where each section can be connected in different ways.

A production process where a product moves along a conveyor belt, and workers add parts at each station.

Example: Like passing around a craft project in class where each student adds a different decoration.

Any activity that consumes resources without creating customer value.

Example: Walking back and forth to get supplies because they're stored far away. 

Unevenness in workload.

Example: A restaurant overcrowded during mealtimes, but empty at other times. 

A metric that measures customer loyalty by asking how likely they are to recommend a product or service.

Example: Rating how likely you are to tell your friends about your favorite restaurant.

Activities that don't contribute to what customers want.

Example: Moving supplies back and forth between storage rooms.

A Pareto chart is a bar graph combined with a cumulative line graph that helps identify the most significant factors contributing to a problem. It is based on the Pareto Principle (80/20 rule), which states that roughly 80% of problems stem from 20% of causes. The objective is to separate the vital few from the trivial many.

The idea that 80% of results come from 20% of efforts.

Example: Realizing that most of your study success comes from focusing on a few key subjects.

(Plan-Do-Check-Act) Method for continuous improvement.

Example: Planning your basketball shot, taking it, seeing if it worked, then adjusting. 

Payment based on units produced rather than time worked.

Example: Getting paid $1 for each car you wash instead of hourly. 

A payment method where workers are paid based on the number of items they produce.

Example: Getting paid $1 for each bracelet you make instead of an hourly wage.

Error-proofing systems to prevent mistakes.

Example: USB ports that only fit one way. 

Drawing out steps in a process to understand it better.

Example: Drawing the path you take to get ready for school. 

(Quality Improvement Process) Structured way to make things better.

Example: Finding better ways to clean your room faster.

Groups meeting to solve work problems.

Example: Class council meeting to improve recess activities. 

Basic materials used in manufacturing before any processing.

Example: Like the flour and sugar you need before baking cookies.

Finding the real reason problems happen.

Example: Discovering your plant died because the watering schedule was forgotten. 

System for rapidly reducing equipment changeover time.

Example: Reducing mold change time in plastic injection molding from hours to minutes 

(Standard Operating Procedure) Written steps for doing tasks.

Example: Recipe for making your favorite sandwich. 

Map showing how people or things move.

Example: Drawing lines on a school map showing your path between classes.

A measure of how spread out numbers are in a data set.

Example: Like seeing how much your test scores vary from your average score.

Making tasks consistent.

Example: Everyone in class follows the same steps to line up.

Organized storage area for quick part pickup.

Example: School supply cabinet where everything has its place. 

Production pace needed to meet customer demand.

Example: If a factory operates 8 hours and customers demand 480 units daily, takt time is 1 minute per unit. 

An award recognizing companies for excellence in quality management practices.

Example: Like winning a school award for having the best science project based on thorough research and accuracy.

A period of social and political reform in the United States from the 1890s to the 1920s aimed at addressing issues caused by industrialization.

Example: Like a time when your school makes big changes to improve fairness and student well-being, such as healthier lunches and better classroom rules.

Basic motion in a task.

Example: Reaching for your pencil is one basic motion. 

Amount produced in given time.

Example: Number of homework problems completed per hour. 

Time to develop and launch new product.

Example: Time from idea to selling your first batch of homemade bracelets.

(Toyota Production System) Toyota's way of making cars efficiently.

Example: Like having perfect system for cleaning your room quickly. 

(Voice of Customer) What customers want and need.

Example: Listening to what toppings friends want on pizza. 

Goal of making everything perfect first time.

Example: Getting all spelling words right on first try. 

(Zero Quality Control) A method focusing on error-proofing and process improvements to eliminate the need for inspections.

Example: Using spell-check while typing to prevent errors instead of correcting them later.