Gemba in kaizen system stands for "" shop floor or work place / work station ""
Kaizen proposes that any change or improvement is intiated from shop floor rather than
from board rooms or managers cabin . It recommends that to bring any improvement one
has to go the place where the action takes place . kaizen proposes that the best person to
suggest any ideas is the one who is doing the job ie the shop floor worker .
Its the process where we have less mistakes or errors in process ,This can be achieved
through various tools or equipments which can either detect or prevent errors from
occuring at first place.Poka Yoke aims at achieveing zero defects .
Takt time can be defined as the maximum time allowed to produce a product in order to
meet demand. It is derived from the German word taktzeit which translates to clock cycle.
There is a logic therefore to setting the pace of production flow to this takt time. Product
flow is expected to fall within a pace that is less than or equal to the takt time. In a lean
manufacturing environment, the pace time is set equal to the takt time
Jidoka, means, in the production context, not allowing defective parts to go from one work
station to the next. It specifically refers to machines or the production line itself being able
to stop automatically in abnormal conditions (for example, when a machine breaks down or
when defective parts are produced). This Autonomation (as it is also called) allows
machines to run autonomously, as they will stop when a problem occurs. Ultimately, it is
about transferring human (or better) intelligence to machines.
Jidoka is also used when individual people encounter a problem at their work station. They
are responsible for correcting the problem - if they cannot, they should stop the line rather
than let the defective