Right-sized technology, 208
Ringi sho, 387
Risk taking, 461–466
Robot, 177, 200
Role model lean customer, 290
Rolled through-put yield, 91
Root blame, 347
Root cause analysis, 13, 341–355
Rother, Mike, 38, 45, 410n
Rule 1 (always satisfy the customer), 102
Rule making, 186
Runkle, Donald L., 297
Rushing to short-term gains, 50
Sacrifice, 34
Safety, 360
Safety standards, 120
Scheduled, 108
Scientific management, 434
Self-inflicted variability, 74
Self-monitoring machines, 177
Sense of purpose, 18–19
Sensei,437–439
Sequence pull system—engineering, 104–105
Sequenced flow, 47, 100, 101
Sequenced pull, 100, 104, 108
Sequenced queue, 107
Sequential and concurrent continuous improvement,
52–53
Shared purpose, 12
Shikamura, Akio (Alex), 421
Shingo, Shigeo, 71
Shook, John, 38, 45, 410n
Short cycle time jobs—one piece flow, 92–94
Short-term countermeasures, 365
Simplicity, 190
Simplified information flow, 47
Simulation, 360, 361
Simultaneous engineering, 284
Single minute exchange of dies (SMED), 71
Single piece flow, 89–91, 92–94
Single-piece flow (See alsoOne-piece flow)
Sink or swim method, 248
Six Sigma, 172, 371, 398
Six Sigma changeover reduction, 404–406
Slice and dice, 161–163
Small batch production, 185
Small issues, 311, 313
SMART objectives, 451
SMED, 71
Smoothing demand, 148–151
Sobek, D., 272n
Social pact, 25–26
Sociometric stars, 434
Soft side benefits, 54
Solving problems (seeProblem solving for continuous
learning)
Specialists, 224
Spiral model of continuous improvement, 49–50, 51
Stability phase, 56–79
basic stability, 56
clearing the clouds, 58
Stability phase, (Cont.):
consolidating waste activities, 65–71
5S, 64
instability, 57
isolating variability, 74–77
large waste, 60
leveling, 77–78
objectives of stability, 58–59
operational availability, 71–74
reflection, 79
stand in the circle exercise, 60–61
standardized work, 61–64
strategies/tools, 59–60
traps, 59
Stack chart, 350, 351
Stack lights, 178
Staggered release, 105
Staltmanis, Andris, 422
Stamping operations, 102
Stand in the circle exercise, 60–61, 425
Standard procedures, 121–122
Standard specifications, 120–121
Standard work/IPCS audit form, 453
Standardization, 10, 111–144
auditing, 134–135
baseline for continuous improvement, as, 135
coerciveness, 111–113
environmental standards, 120
ISO controlled operator instruction, 133
myths, 122–124
objective, 114–117
prerequisites, 125
quality standards, 119–120
reflection, 142–144
safety standards, 120
standard procedures, 121–122
standard specifications, 120–121
standardized work documents, 126–131
strategies, 117, 118
takt time, 136–139
tips, 117, 128, 136
tools, 118
traps, 125, 133
types of, 118–119
uses, 61–64, 133
visual controls, 139–142
waste analysis tool, as, 61–64
waste elimination tool, as, 141
work standards, 113–114
Standardized work chart, 126–127
Standardized work combination table, 128–131
Standardized work documents, 126–131
Statistics, 371
Status story, 377, 379
Stopping to fix problems, 81, 171–197
case examples, 175–176, 184, 187–190, 191–193
error proofing, 186–195
inspection, 184–185
jidoka, 177
minimizing line stop time, 182–183
overview, 174
poka yoke,186–195Index 473