Index

A
Abstraction, 151
Active root cause verification, 361
Activity network, 586
Advanced product quality planning
(APQP), 7, 8, 18, 32, 257258
characteristics, and relationship
with production part approval
process, 911
control plans, 263
fundamental elements of, 260262
initiatives, 258259
reporting, 259260
reviews, 207
risk assessment, 262263
Schaefflers characterization, 264274
supplement K worksheet, 263, 275
Affinity diagram, 586
AIAG, see Automotive Industry Action
Group (AIAG)
All around symbol, 308
All around this side of parting line, 308
Amateur errors, 203
American Society of Mechanical
Engineers (ASME), 305, 306,
308, 316, 320, 324326, 328
Analogy, 151
Anderson-Darling statistic, 394
Andon, 100
Angularity, 308
ANOVA, 244, 252, 445
Applied problem solving (APS),
152,200
APQP, see Advanced product quality
planning (APQP)
APS, see Applied problem solving (APS)
APW, see Average production weekly
(APW)
Arc length, 308
Area sensors, 461
ASME, see American Society of
Mechanical Engineers (ASME)
AS 9100, 13, 15, 51

Audit
checklists and, 195196
definition, 179
performing, 182183
error-proofing audit, 193
layered process auditing (LPA),
188193
process audit, 184188
product audit, 183184
preparation, 463503
successful, 55
types, 180182
Auditing, definition of, 179
Automotive Industry Action Group
(AIAG), 397, 441
CQI-8, 188
Autonomation, 92, 104
Average production weekly (APW), 285,
291, 300
B
Balanced scorecard, 69, 71
Bar chart, 84, 248, 251, 586587
Beam sensors, 461
Benchmarking, 5, 85, 117, 414
Bilateral tolerance, 316
Birdbeak, 326
Black belts, 401
Brainstorming, 121, 152, 222223, 587
Breakthrough, 158
Business costs, 224
BX life, 395396
C
Capacity analysis, 289
capacity analysis report (CAR), 291293
capacity information maintenance,
301302
goal, 289291
overall equipment effectiveness
(OEE), 293294
for availability, 296
605

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606

demonstrated, 296297
demonstrated OEE
improvement,295
enablers to improve demonstrated
OEE, 298
evaluation, 294295
for performance efficiency, 296
for quality rate, 296
required, 298299
reaction and plan expectations,
300301
shared loading analysis and, 299300
thought starters for supplier capacity
volume improvement and,
302303
total allocation, 300
Capacity analysis report (CAR), 291293
CAR, see Capacity analysis report (CAR)
Cause and effect, 122, 587
CEO, see Chief executive officer (CEO)
Champion, 340, 353, 364, 370371
Six Sigma, 401402
Changeover time, 561562
Chargebacks, 392
Checklists, 183, 195196, 449452, 533
Check sheet, 119, 587588
Chief executive officer (CEO), 109
Chief process officer (CPO), 109
Chronic problem, 158
Circular runout, 330
CMM, see Coordinate measuring
machine (CMM)
Coaxial controls overview, 330
Color marking sensors, 461
Column chart, 579
Complete data, 394
Comprehension model, 152153
Concentricity, 308
Conical taper, 308
Contact method, 200
Continual improvement, 6971, 108, 112,
130, 414; see also Kaizen
board, 382383
control strategies, 101
items of concern in
one-piece flow, 7477
process flow diagram, 7785
value stream map, 8692
objective of, 116

Index

process, 116117
process teams, 7174
tools used, 586599
visual factory (6s), 92101
visual management and
relationships, 101
Continuous feature symbol, 308
Continuous flow, 566567
Contour plot, 396
Control chart, 122, 139, 144, 217, 444,588
Controlled radius, 308309
Control method, 220, 444
Control plan, 19, 3132, 263, 278, 450, 523
gauge, 527
and operator instructions, 33, 443444
requirements, 14
simplified, 524
Control points evaluation, 80
Coordinate measuring machine (CMM),
241, 322, 325
Counterbore/spotface, 309
Countersink, 309
CPO, see Chief process officer (CPO)
Critical items, for customers, 411412
Critical success factors, 52
CtM (3D CAD data file), 313
Cultural costs, 224
Customer cross-functional teams, 6, 7,
27, 3637
Customer satisfaction, 46, 116, 130, 386,
532, 550
Cycle time, 82, 105, 574, 576
Cylindricity, 309
D
Datum, 324327, 331332
feature, 309
and target datum symbols, 323
targets, 309, 325326
Datum reference frame (DRF), 323
Datum translation symbol, 312
DCOV, see Define, characterize, optimize,
and verify (DCOV) model
DCP, see Design control plan (DCP)
Decision tree, 588
Defect, 202, 335, 398, 455
comparison with error, 205206,
455456

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Index

comparison with mistake, 199, 200,

218, 456
definition, 565
relationship with Sigma, 399
zero, 116, 208, 210212, 216, 382
Define, characterize, optimize, and
verify (DCOV) model, 401
and statistical process control
(SPC),149
Define, measure, analyze, design, and
verify (DMADV), 400401
Define, measure, analyze, improve, and
control (DMAIC), 399400
and statistical process control
(SPC),149
Demand-based flow manufacturing, see
Lean manufacturing
Department improvement teams
(DITs), 175
Deployment flowchart, 581
Depth/deep, 309
Descriptive geometry, 305
Design control plan (DCP), 440, 441
Design failure mode and effect analysis
(DFMEA), 37, 207, 278, 313
Design of experiments (DOE), 145, 589
Destructive testing, 248
DFMEA, see Design failure mode and
effect analysis (DFMEA)
Diameter, 309
Dimension origin, 309
Displacement sensors, 461
Disposition, 2324
approval
achieved, 25
denied, 24
revoked, 25
nonmanufacturing site, 26
required, 24
tier 2, 25
waived, 2526
working toward quality system, 24
DITs, see Department improvement
teams (DITs)
DMADV, see Define, measure, analyze,
design, and verify (DMADV)
DMAIC, see Define, measure, analyze,
improve, and control (DMAIC)
Dock to dock (DTD), 558559

607

DOE, see Design of experiments (DOE)

Double feed sensors, 461
DRF, see Datum reference frame (DRF)
DTD, see Dock to dock (DTD)
DtM (2D drawing), 313
DtMC (2D drawing and 3D CAD data
file), 313
8D model, 156, 208, 335336
application criteria, 336337
interim containment action (ICA),
352353
evaluating questions, 354355
process guidelines, 353354
PCAs choosing and verification for
root cause and escape point, 362
evaluating questions, 363364
process guidelines, 362363
PCAs implementation and
validation, 364365
evaluating questions, 366367
ICA removal, 365
process guidelines, 365366
problem description, 344346
development process, 348351
evaluating questions, 351352
process guidelines, 346348
problem recurrence prevention,
367369
evaluating questions, 371372
process guidelines, 369371
problem-solving process preparation,
337339
process flow and team establishment,
339340
membership, 343344
process guidelines, 342343
team composition, 340342
warming up, 343
root cause and escape point definition
and verification, 355356
evaluating questions, 357358
generic simple root-cause
analysis, 358
guidelines, 356357
root cause determination, 358361
root cause verification, 361
supplemental tools, 361
success factors, 378379
summary evaluation, 375378

608

team and individual contributions

recognition, 372373
evaluating questions, 374375
process guidelines, 373374

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E
Employee balance chart, 575576
Employee readiness and training
review, 32
Enterprise alignment and continuous
process improvement, 93
Error and defect, comparison
between,206
Error-proofing; see also Poka-yoke
approaches, 565
audit, 193
partial form of, 194
benefits, 566
defect definition, 565
error definition, 565
method, 565566
sides, 564
teams, 565
Evaluation model, 153
Execution and communication
model,153
Executive management, 116, 401, 402
F
Facilitator, 341342
Failure mode and effect analysis
(FMEA), 3132, 145, 207, 397,
440, 589
reviews, 208
Failure rate vs. time plot, 396
Fake flow, 92
Fast response board (FRB), 6970, 72
Fault tree analysis, 589590
FCF, see Feature control frame (FCF)
FDJ, see Final data judgement (FDJ)
Feature control frame (FCF), 309,
323324
Feature of size (FoS), 319322, 325,
328329
Fiber sensors, 461
FIFO, see First-in first-out (FIFO)

Index

Final data judgement (FDJ), 36

First-in first-out (FIFO), 466, 472, 478,
493, 572
First-party audit, 180
First time quality (FTQ), 70, 471
First time through (FTT), 556558
5-step model, 160
correction verification, 164
problem correction, 163164
problem recurrence prevention,
164165
problem root cause finding, 163
problem selection, 163
recycle, 165
5 Whys model, 156, 212
5X number of places, 310
Fixed-value method, 200
Flatness, 306, 309
Flow chart, 119, 590; see also Process flow
diagram
basic (macro level), 580581
deployment, 581
opportunity, 581
process, 77, 87, 268, 542, 590, 582
FMEA, see Failure mode and effect
analysis (FMEA)
Focal objects method, 152
Force field analysis, 122, 590
Ford production system (FPS), 382384
Forgetfulness, 202203
FoS, see Feature of size (FoS)
FPS, see Ford production system (FPS)
FRB, see Fast response board (FRB)
Free state variations, 309
FTQ, see First time quality (FTQ)
FTT, see First time through (FTT)
Function analysis, 405
G
Gant chart, 591
Gauge repeatability and reproducibility
(GR&R), 33, 230234, 278, 445,
474, 519520
in Minitab, 238240
nested, 250
selection process for crossed, 244
GD&T, see Geometric dimensioning and
tolerancing (GD&T)

609

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Index

Geometric dimensioning and

tolerancing (GD&T), 305306
coaxial controls overview, 330
datum, 324327
targets, 325326
datum and target datum
symbols,323
diamond P and D requirements,
315316
drawing types, 313
feature control frames (FCF),
323324
feature of size (FoS), 319321
independency, 323
key elements to review, 330332
MMC and LMC, 332
regardless of feature size (RFS),
332334
language, 306312
least material condition (LMC), 322
maximum material condition
(MMC), 321
orientation, 327
projected tolerance zone,
328329
rules applied and things to
remember, 327
profile controls, 329330
circle U modifier, 329
title blocks and notes, 314315
tolerance modifying symbols, 323
tolerance types, 316317
basic dimensions, 317319
line conventions on production
drawings, 319
virtual condition, 322
Geometric tolerance, 316
Good parts produced (GPP), 297
GPP, see Good parts produced (GPP)
GR&R, see Gauge repeatability and
reproducibility (GR&R)
Green belts, 401
Green rating, for items, 96, 259
GROW model, 153154
Growth, in quality perception, 411
H
Histogram, 84, 122, 591

How to solve it model, 154

Hypothesis testing, 152
I
IATF, see International Automotive Task
Force (IATF)
ICA, see Interim containment action (ICA)
IDEFO (ICOM definition), 591592
Identification mistakes, 203
Inadvertent mistakes, 203204
Incoming quality control, 33
Independency symbol, 310
Information inspection, 216
In-process supermarket, 567568
Intentional mistakes, 204
Interim containment action (ICA),
352353
development, 376
evaluating questions, 354355
process guidelines, 353354
removal, 365
International Automotive Task Force
(IATF), 14, 280
International Standard Organization
(ISO), 127129; see also individual
entries
individual certifiable clauses, 131
analysis, measurement, and
improvement requirements,
134135
management requirements, 132133
management system general
requirements, 131132
resource requirements, 133
services and products
requirements, 133134
key elements, 129131
pending changes for 2015 revision,
135136
Interval/left censored data, 394
ISO, see International Standard
Organization (ISO)
ISO 9001, 1314, 31, 51, 127, 131, 179
ISO 13485, 51
ISO 14000, 52
ISO 14001, 14, 15, 23, 49, 439
ISO/TS 16949, 1516, 23, 49, 51, 182,
439440

610

J
Jidoka principle, 92, 104, 385
JIT, see Just-in-time (JIT)
Judgment inspection, 216217
Just-in-time (JIT), 385, 387, 388, 566

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K
Kaizen, 112, 158, 383, 385, 580, 582; see
also Continual improvement
Kanban, 385, 568572
Kano model, 130, 592
Kappa statistic, 592
calculation, 235236
Cohen, 235
Fleiss, 235
Kendalls coefficient of concordance,
235, 236
Kepner-Tregoe model, 154
L
Lack of standards mistakes, 204
Lateral thinking, 152
Launch overlay, 48
Layered process auditing (LPA),
188193, 195
benefits of, 192
business impact of, 192193
elements of, 188
indicating documentation and
progress, 191
typical format of, 189
typical form of management, 190
typical form to track
nonconformances in, 196
Leadership, significance of, 130
Lead time, 86, 8889, 228
Lean manufacturing, 103104, 577; see
also individual entries
easier application for, 108112
goals and strategy, 105106
lean deployment guideline sheet,
554556
lean functions, for lean enterprise, 554
model, 156, 158
steps to achieve systems of, 106108
warning for, 112113

Index

Lean sensei, 104

Least material condition, 306, 309, 322,
332, 333
Liability costs, 224
Life data analysis, 394395
Limited involvement overlay, 4849
Line graph, 84, 592593
Long-term corrective action, 221
LPA, see Layered process auditing (LPA)
LRT P, 394
M
Manufacturing capability
demonstration, 442447
planning, 31, 439442
Manufacturing site assessment (MSA),
2225, 27
typical form, 2934
Maslows theory of needs, 505, 512516
Master black belts, 401
Material delivery date (MDD), 261
Matrix data analysis chart (MDAC), 593
Matrix diagram, 593
Maximum material condition, 310, 320,
321, 332, 333
Maximum production weekly (MPW),
285, 291, 300
MDAC, see Matrix data analysis chart
(MDAC)
MDD, see Material delivery date (MDD)
Mean life, 395
Means-ends analysis, 152
Measurement system analysis,
227229,278
data types, 229230
Minitab, 230
attribute, 235241
gauge repeatability and
reproducibility (GR&R), 230234
key to success, 253254
percentage numbers explanation,
248, 252253
possible bias causes, 254
possible linearity issues, 254
repeatability and reproducibility
issues, 253
variable, 241248, 249252
Metal passage detectors, 461

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Index

Minitab, 394; see also under

Measurement system analysis
Mistake proofing, see Poka-yoke
Misunderstanding mistakes, 203
Morphological analysis, 152
Motion-step method, 200
Movable datum targets, 310
MPW, see Maximum production weekly
(MPW)
MSA, see Manufacturing site assessment
(MSA)
Muda (non-value-adding work), 103
Mura (unevenness), 104
Muri (overburden), 103
N
NAT, see Net available time (NAT)
Net available time (NAT), 297
Net ideal cycle time (NICT), 297
New-tooled end-item (NTEI), 28
NICT, see Net ideal cycle time (NICT)
Nominal group technique, 121, 593594
Non-value-added activity, 88, 209, 215
NTEI, see New-tooled end-item (NTEI)
O
Observe, orient, decide, and act (OODA)
loop, 154155
OEE, see Overall equipment
effectiveness (OEE)
One-piece flow, 7477
On-site evaluation, 3740
OODA, see Observe, orient, decide, and
act (OODA) loop
Opportunity flowchart, 581
Original wastes, 105106
Overall equipment effectiveness (OEE),
34, 70, 9192, 293294, 559561
for availability, 296
demonstrated, 296297
enablers to improve, 298
demonstrated OEE improvement, 295
evaluation, 294295
for performance efficiency, 296
for quality rate, 296
required, 298299
improving, 299

Overlays, 48
launch overlay, 48
limited involvement overlay, 4849
quality overlay, 48
P
PACT principle, 512
Painter chart, 85
Parallelism, 310
Pareto chart, 70, 8485, 121, 594
Pareto principle, 119
Parting lines, 310
Part submission warrant (PSW), 7, 35,
40, 42, 388, 452
Passive root cause verification, 361
Paynter chart, 122
PCAs, see Permanent corrective actions
(PCAs)
PDCA, see Plan, Do, Check, Act (PDCA)
model
PDPC, see Process decision program
chart (PDPC)
Permanent corrective actions
(PCAs),336
choosing and verification for root
cause and escape point, 362,377
evaluating questions, 363364
process guidelines, 362363
implementation and validation,
364365, 377
evaluating questions, 366367
ICA removal, 365
process guidelines, 365366
Perpendicularity, 310
PFMEA, see Process failure mode and
effect analysis (PFMEA)
Physical layout, 583586
Pitch, 573575
PITs, see Process improvement teams
(PITs)
Plan, Do, Check, Act (PDCA) model,
7273, 112, 127129
comparison with OODA loop, 155
typical form to generate and
summarize events of, 74
Planning, analysis, and synthesis
model, 153
Point-to-point comparison, 392

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612

Poka-yoke, 82, 199, 455

common error-proofing devices and,
460461
corrective action, 221223
defects and errors, 455456
development process, 453
essentials, 204209
generic worksheet and example, 454
historical perspective, 199200
human mistakes correction
approaches, 213220
mistake alerting signals and, 460
mistake types and accompanying
causes and, 456460
presentation of findings, 224
red flag conditions, 220221
steps and application, 210213
strategy, 200202
systems, 202204
types of, 200
zero defects concept in, 210, 211, 212
Positioning sensors, 461
Position tolerance, 310, 328329, 333
Post-it Notes, 576
PPAP, see Production part approval
process (PPAP)
Precap inspection, 183
Prevention and detection approaches,
comparison of, 206207
Preventive maintenance and
housekeeping, 34
Prioritization matrix, 594
Probability of failure, 395
Probability plot, 396
Problem solving and corrective
actions, 34
Problem-solving methodology, 151
cycle, 160165
definition, 158160
model types, 151158
process improvement cycle and,
167176
tools, 165167
Process audit, 184188
benefits of, 187
business impacts of, 187188
circumstances to conduct, 187
partial audit form, 185186
steps in, 185

Index

Process capability, 20, 31, 171, 272,

439442, 595
Process decision program chart (PDPC),
595
Process efficiency, 228
Process failure mode and effect analysis
(PFMEA), 32, 207, 278
Process flow diagram, 77, 278; see also
Flow chart
as is phase, 77
mission statement
development,79
process boundaries definition, 79
process definition, 79
process owner and team member
selection and identification, 78
process scope selection, 79
process selection for investigation
and study, 78
could be phase, 85
should be phase, 7985
Process improvement cycle, 167168
fourteen-step process, 168173
Process improvement measurement, 83
Process improvement teams (PITs), 175
Process lead, 59, 65
Process monitoring, 84
Process specialists, 65
Process submission warrant,
280282,286
full, 286
interim, 286287
rejected, 287
Process variability monitoring and
reduction, 33
Product audit, 182, 183184, 502
Product development timing, 35
organizational timing principles,
68
timing example of automotive
industry timing, 811
Production part approval process
(PPAP), 7, 8, 32, 277281
actual requirements, 286
capacity analysis, 283284
capacity report, 285
checklist, 449452
key clarifications, 286287
misconceptions about, 285286

613

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Index

relationship with advanced product

quality planning (APQP), 911
submission levels and approvals,
281282
verification flow, 282283
Production system implementation,
386387
Production system model, based on
American engine plant,
387388
Product realization, 1820
Profile control, 329330
circle U modifier, 329
Profile of a line, 310
Profile of a surface, 310
Profile tolerance, 308, 312, 329
Program engineer, 6061
Program target compatibility (PTC), 36
Projected tolerance zone, 310
Project risks minimization, 402403
PSW, see Part submission warrant (PSW)
PTC, see Program target compatibility
(PTC)
Pull system, 104, 386, 493, 554556, 567
P-value, 394
Q
QFD, see Quality function deployment
(QFD)
QMS, see Quality management system
(QMS)
QOS, see Quality operating system
(QOS)
Quality audits, 179
Quality function deployment (QFD),
145, 170, 414
Quality management system (QMS),
17, 51
Quality operating system (QOS), 19, 110,
117122, 440
implementation, 122, 123, 124
meeting summary, 122126
need for quality and discipline
issues, 115117
potential measurables, 120
Quality overlay, 48
Quality system, of original equipment
manufacturing (OEM), 13

customer-specific standards, 2123

disposition, 2326
industry standards certification n,
1521
ISO 14001, 15
ISO 9001 certification, 1314
control plan requirements, 14
Quick changeover method, 561563
R
Radius, 310
Rapid problem resolution (RPR),
155156
R chart, 248, 251, 252
Recorder, 341
Red flag conditions, 220221
Red rating, for items, 9596, 259, 260
Reference dimension, 310
Regardless of feature size, 306, 310, 320,
332334
Regardless of material boundary, 306,
320, 322
Relationship diagram, 595596
Reliability vs. time plot, 396
Representation model, 153
Resident and plant engineer, 6263
Resource management, 18
Resources, conscious use of, 117
Responsible supplier indicators, 412414
Risk priority number (RPN), 207, 397
Root-cause analysis, 116, 152
Root cause and escape point definition
and verification, 355356,
376377
analysis, 116, 152, 358359
evaluating questions, 357358
guidelines, 356357
permanent corrective actions (PCAs),
362, 377
evaluating questions, 363364
process guidelines, 362363
root cause determination, 358361
root cause verification, 361
supplemental tools, 361
Roundness, 311
RPN, see Risk priority number (RPN)
RPR, see Rapid problem resolution
(RPR)

614

Run chart, 110, 122, 125

Runout, 311, 312, 317, 330

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S
Safety and health achievement
recognition program
(SHARP), 382
Safety, Quality, Delivery, and Cost
(SQDC) board, see Fast
response board
Scatter diagram, 122, 596
SCCAF, see Special Characteristics
Communication and
Agreement Form (SCCAF)
Second-party audit, 180
Segmentation, 45
applications, 4950
definition, 4546
model, 4748
overlays, 48
launch overlay, 48
limited involvement overlay,
4849
quality overlay, 48
Self-check, 215
comparison with successive
checks,217
SfQ, see Sourcing for quality (SfQ)
Shared loading analysis, 299300
SHARP, see Safety and health
achievement recognition
program (SHARP)
Short-term corrective action, 221
Shut down method, 220
Simplification process, 8283
Simulation in lean, 596597
Single minute exchange of dies (SMED),
8991
Site engineer, 5960, 62, 64
Six Sigma, 148149, 175, 383, 398399
forms, 505507
analysis, 524
control, 526
definition, 512516
improvement, 525526
measurement, 517524
miscellaneous, 526528
typical, 528553

Index

methodology, 399
define, measure, analyze, design,
and verify (DMADV), 400401
define, measure, analyze,
improve, and control (DMAIC),
399400
Six Sigma mastery level, 401402
requirements to understand, 505,
508512
6S principle, 9499, 101
Slope, 311
Slowness mistakes, 204
SMED, see Single minute exchange of
dies (SMED)
Source inspection, 215, 217
Source inspection audit, 183184
benefits of, 184
business impact of, 184
Sourcing for quality (SfQ), 35
general procedures, 43
emergency resourcing to
nonqualified facility, 44
new and initial sourcing and
nonemergency resourcing, 43
sourcing to sites with waiver,
4344
supplier sourcing, 36
cross-functional teams formation,
3637
priority suppliers selection, 36
team kickoff meetings beginning,
3742
Spaghetti diagram, 582
SPC, see Statistical process control (SPC)
Special Characteristics Communication
and Agreement Form
(SCCAF), 275
Spherical diameter, 311
Spherical radius, 311
Spike, 392
Sporadic problem, 158
Spot face, 311
Square, 311
SREA, see Supplier request for
engineering approval (SREA)
Standardization, 27, 7677, 81, 97, 158,
583; see also International
Standard Organization (ISO)
of measurable, 119

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Index

of operator instructions, 443

of work and tasks, 111, 383, 471
Standardized work instructions (SWIs),
472473
Standard work, 577579
Standard work-in process, 77
Statistical process control (SPC), 33, 139,
171, 444
model, 139141
continuous improvement of
process performance, 146148
process controls definition and
establishment, 144146
process identification and
definition, 141
process ownership and
responsibilities establishment,
141144
seven-step approach to implement,
147148
Six Sigma and, 148149
Statistical tolerance, 311
Straightness, 311
Stratification, 122
Streamlining process, 8182
String diagram, 597
Subsupplier quality management, 32
Supplement K worksheet, 263, 275
Supplier development, 5152, 188, 412
benefits, 5455
fundamentals, 5254
Supplier engagement, 68, 2728, 36, 61
Supplier launch success, 6
Supplier request for engineering
approval (SREA), 388390
service unique products, 390
supplier risk for not following, 391
temporary, 390391
Supplier technical engineer, 57
miscellaneous functions, 64
specific categories, 5964
stakeholders specific responsibilities,
5859
strategy and business, 6465
Surprise mistakes, 204
Surrogate overall equipment
effectiveness, 294295, 297
Survey, 193, 569, 597
Suspended/right censored data, 394

SWIs, see Standardized work

instructions (SWIs)
Symmetry, 312
Synergistic approach, to problem
description, 344345
System complexity, 228
Systems engineering, 402404
T
Table, 597598
Tact time, 75
Takt time, 7576, 573, 575577
Tall bar chart, 248
Tangent plane, 312
Tap sensors, 461
Target point, 312
Team and individual contributions
recognition, 372373, 378
evaluating questions, 374375
process guidelines, 373374
Team kickoff meetings beginning, 3742
Team leader, 335, 341, 383, 480
Team members, 37, 40, 71, 78, 341, 345
composition of, 222
optimum selection of, 343344
Technical specialists, 6364, 65
Testing and engineering specifications,
3334
Third-party audit, 180
3 5 Whys model, 156, 157, 212
Three-Legged 5 Whys, 345346
Tolerance, 244245, 252, 312, 327
modifying symbols, 323
position, 310, 328329, 333
profile, 308, 312, 329
projected tolerance zone, 328
statistical, 311
types, 316317
basic dimensions, 317319
line conventions on production
drawings, 319
zero, 116
Tool tryout (TT), 40
Total production system (TPS), 381382
Fords approach, 382384
Total runout, 312
Toyotas system of preventive
maintenance, 103104

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616

Toyota production system, 384385

TPS, see Total production system (TPS)
Trail-and-error, 152
Tree diagram, 598
Trend chart, 84
Trimetrons, 461
TRIZ model, 156
TT, see Tool tryout (TT)
Turnaround time, see Lead time
U
Unilateral and unequally disposed
profile tolerance, 312
Unilateral tolerance, 316
Unplanned downtime, 70
V
Validation, definition of, 403
Value-added activity, 88, 209, 215
Value-added assessment, 81
Value analysis, 598
Value analysis job plan, 405
Value engineering, 404406
Value stream map, 8692
Value streams, 298299, 573
Verification, definition of, 403
Verification audit, 182
Verification of Supplier Capability, 4042
Verification of Supplier Capacity, 40, 42
Verification of Supplier Failure Mode
Avoidance Strategy and
Manufacturing Plan, 3738
Verification of Supplier Launch
Preparation, 3839
Vibration sensors, 461
Visual factory (6s), 92101, 563
levels
visual controls, 563564
visual display, 563
Visual management, 101
V-model, 402403
Voting, 598599

Index

W
Walk-though process, 80
Warning method, 219220
Warranty, 391393
Warranty time, 395
Waste in process issues, 117
Weibull distribution, 393397
Welding position indicators, 461
Willful mistakes, 203
Winwin philosophy, 409, 411, 414
Workload balancing, 575577
Workplace organization steps, 564
Worksheet
action plan, 540
cost/function, 541
cost index, 543
data in, 237, 242
function identification, 546
manufacturer information
gathering, 544
mistake-proofing, 454
proposal selection, 538539
Supplement K, 263, 275
T-chart, 537
triple 5-Why analysis, 534
X
Xbar chart, 248, 251
Y
Yellow rating, for items, 96, 259
Yokoten, 580
Z
Zero defects, 116, 208, 216, 382
flow and cycle, comparison with
improvement cycle, 211
goal of, 208
in mistake proofing, 210
process overview, 212