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Lean Foundations & Takt
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Lean on the Floor
Check this point against current official guidance before relying on it.
- Lean lives in section I.B — concepts, value streams, and takt time.
- Eight wastes, one acronym: DOWNTIME.
- This is floor-walking knowledge: Gemba, flow, pull, perfection.
The Named Concepts
Check this point against current official guidance before relying on it.
- Theory of constraints: the bottleneck sets throughput.
- Gemba: go to the real place and watch the actual work.
- Spaghetti diagram: trace the walking; JIT: make only what's needed, when needed.
Takt Time, Worked
Check this point against current official guidance before relying on it.
- 480-minute shift, 60 minutes of breaks → 420 available.
- Demand: 210 units per shift.
- Takt = 420 ÷ 210 = 2.0 minutes per unit.
DOWNTIME — the 8 Wastes
Check this point against current official guidance before relying on it.
- Defects, Overproduction, Waiting, Non-utilized talent...
- ...Transportation, Inventory, Motion, Extra-processing.
- Transport moves PRODUCT; motion moves PEOPLE.
Quick Self-Check
Check this point against current official guidance before relying on it.
- In your head:
- A 450-minute day must produce 150 units — what's the takt?
- And is a forklift trip transport or motion?