“Form, fit, and function” are most commonly discussed in relation to the design of an object, or when considering if a process is value added or not. Form: Form is the physical characteristics of the product. It includes things like shape, weight, color, material, etc. Fit: Fit is short for Read more…
Feeder lines are a very specialized branch of a main assembly line. Generally, they are used when there is a different amount of work required for an option or for the most time intensive product on a mixed-model assembly line. Feeder lines will run on their own takt time. The Read more…
A functional layout is a workplace organization in which processes are organized by the type of work (function), rather than by value stream or in a cellular configuration where sequential process steps are located in close proximity. In a functional layout, for example, the cutting machines would be in one Read more…
“Full-time equivalent”, or “FTE” is a way to normalize staffing decisions. In the modern workforce, particularly in administrative environments, employees perform multiple functions or don’t work standard 9-to-5 schedules. Using FTE to determine the size of the workforce assigned to a process makes accurate productivity and cost measures possible. A Read more…
A future state value stream map (VSM) is simply a projection of how a value stream should look in the future, generally 6 to 12 months. When a current state value stream map is created, problem areas become apparent. The bottlenecks where inventory piles up, processes with poor quality, and Read more…
A FIFO lane (First In, First Out) helps manage flow in a process. It is exactly what it sounds like. The first item coming into a process is the first one worked on. FIFO lanes provide consistency and predictability. They create a link between a process and its upstream supplier. Read more…
First pass yield (FPY) is a metric that indicates the percentage of items moving through a series of processes without any problems. The basic equation for first pass yield is: First Pass Yield = Process 1 Yield * Process 2 Yield *…*Process ‘n’ Yield As you can see, the more Read more…
FIFO (First In, First Out) is most commonly known as an accounting term. It simply means that the first inventory into the accounting system is the first that is recorded as used. The opposite, LIFO, or “Last In, First Out” means that the most recently purchased materials are the first Read more…
The fishbone diagram (a.k.a. cause and effect diagram, a.k.a. Ishikawa Diagram) is a way of linking the causes of a problem to the observed effect. The diagram groups the causes in categories along the spine. The distinctive shape of the tool gives the fishbone diagram its name. This is one Read more…
The FMEA Worksheet (Failure Mode and Effects Analysis) supports the process of managing the risk associated with product or process failures. Traditionally an engineering tool, the FMEA Worksheet is also useful when assessing the risk of a Lean project. Watch Our FMEA Video The basic steps to using the FMEA Read more…
Henry Ford (July 30, 1863 – April 7, 1947) is the founder of Ford Motor Company and the man most widely known as the inventor of the moving assembly line. While the first is true, the second common belief is a bit inaccurate. Ford actually popularized the moving assembly line; Read more…