K

Radical change, revolutionary improvement or reform. These are often changes that affect entire organizations, business practices of business systems.

A team-based improvement workshop typically lasting three to five days during which the team members identify and implements significant improvements within one or more processes. Kaizen events are preceded a preparation phase including selection of team members, setting of targets, and arranging of materials and support for making changes. Kaizen events are followed by a follow-up phase during which open action items are completed, improvements are confirmed, and processes are stabilized.

A method for performing audits of process standards. Kamishibai boards are placed in the workplace, and visited by leaders according to their leader standard work or daily management routine. The cards on the board specify what standard to observe and what defines its "normal" or OK condition. These cards are shuffled periodically and placed in the board to randomize when a process will be audited. Cards have red and green sides, allowing the auditor to indicate normal vs. abnormal status. The term kamishibai originates from a traditional Japanese paper theater that used large cards with painted scenes to tell stories and teach morals.

See also Process Confirmation

A signaling device that authorizes and instructs the production or movement of items in a pull system. Kanban is Japanese for “sign” or “sign board.” Kanban cards often are slips of card stock including information such as part name, part number, external supplier or internal supplying process, pack-out quantity, storage address, the consuming process' address, and barcode or QR code. Kanbans may take the form of triangular metal plates, colored balls, electronic signals, containers, or other forms that convey the required information.

Kanban perform two functions in a production operation, to instruct processes to make products and to instruct material handlers to move products. First type is called production kanban and the second called withdrawal kanban. Production and withdrawal kanbans work together to create a pull system. An operator at a downstream process removes a withdrawal kanban when using the first item in a container. This kanban is placed in a nearby collection box. A material handler collects the kanban from this box. The material handler returns to the upstream supermarket and places the withdrawal kanban on a new container of parts for delivery downstream. When this container is removed from the supermarket, the production kanban on the container is taken and placed in a collection box. The material handler from the upstream process returns this production kanban to the upstream process where it signals the need to produce one container of parts.

Physical signals used in a kanban system to authorize production or movement of goods. These are often printed on cardstock, protected in clear vinyl envelopes, and contain information such as part name, part number, supplier name, pack-out quantity, storage address, the kanban delivery cycle, the consuming process address and a bar code.

A storage container where kanban cards are placed after the contain has been withdrawn and the kanban separated from the container.

The use of simple mechanisms without a dedicated power source to assist in performing work. Karakuri are often powered by gravity, springs, counterweights, pendulums, gears, a pedal or handle, energy from another machine, the flow of water or the weight of a workpiece. Karakuri perform simple tasks such as lifting, conveyance or reorienting materials. Karakuri are often very low cost, hand-made in-house and customized to the needs of a specific process. The guiding principles of karakuri are:

1. avoid using human hands to move objects,
2. avoid spend money to automate,
3. use the force of your equipment,
4. use the wisdom and creativity of the people who do the work,
5. build devices that stop by themselves to prevent unsafe operation

Product characteristics such as fit, function, appearance, or the ability to process or build the product, whose reasonable and expected variation is likely to significantly affect customer satisfaction.

A set of materials, parts, information and tools for performing a specific process.

See Affinity Diagram

See Key Performance Indicator