Value Stream provides an integrated description of how a product passes through all stages of production. This process establishes the value of each section of the value stream. Typically, the value stream will look like a flowchart that outlines all steps in the process or product’s life. This is equally applied to service processes (even back office) as well as manufacturing.

Pull is a method for moving item through a production process. In the pull process, nothing moves forward until it is “called” for by the customer or the next processing step. In a pull system, an item that is sold immediately generates an order to produce another. This is often compared to a grocery store where items are replaced on the shelves as they are used. In this fashion only the most current material is being processed. Pull production results in eliminating wasteful inventory buildups and employs elements of just-in-time delivery, one-piece flow, etc.

Mistake Proofing uses “devices” to prevent defects from passing on to the next process. This approach is an improvement over traditional quality approaches, which evaluate for defects at the end of the process. Mistake proofing requires that process quality checks are built into the operations and to detect errors and stop the process.

Quick Changeover is a concept used to eliminate the need for any adjustment by inventing ways of doing it once and forever with a permanent solution. One of the biggest wastes of resources is the time when resources are not in production. This time is created when resources need to be adapted and adjusted to run a different type of product/services. The ability to rapidly change from one product/service to another is often a key success for many companies. Fortunately there are powerful, quick-change techniques that can be applied to any type of operation.

Six Sigma is a highly structured process to improve quality using specific methods and analytic tools. Six Sigma is a robust continuous improvement strategy and process that includes cultural methodologies such as Total Quality Management (TQM), process control strategies such as Statistical Process Control (SPC) and other statistical tools. It uses a structured systems approach to problem-solving and strongly links initial improvement goal targets to bottom-line results.

Theory of Constraints is based on the fact that, like a chain with its weakest link, in any complex system at any given point in time, there is most often only one aspect of that system that is limiting its ability to achieve more of its goal. For that system to attain significant improvement that constraint must be identified and the whole system must be managed with it in mind.

Kaizen Blitz is an intensive and focused approach to Process Improvement. Kaizen means “continuous improvement” and Blitz means “lightning fast.” This continuous improvement methodology will incorporate all elements of Lean Manufacturing Tools such as the 5Ss, Workplace Organization and Standardization, Cells, Pull, Set-up Reduction, etc. To be successful each team will need to be empowered, they will need to have freedom to make changes, and they will need to be good analyzers, creative, and problem solvers. This combination will allow teams to make rapid improvements to a specific product or process.