GembaDocs Logo Main White
Login
Try for Free

Lean Cave Home

Learn
Be Inspired
Resources
Help

Lean & GembaDocs dictionary

Plain-language definitions for lean manufacturing terms and GembaDocs platform concepts. Use the search or filter by category to find what you need.

#

A

B

C

D

E

F

G

H

J

K

L

M

O

P

Q

R

S

T

V

W

#

3S

Lean

A simplified version of 5S focused on the three most essential steps: Sort, Shine, and Standardise. Used by teams who want to establish basic workplace organisation before committing to the full 5S framework.

5S

Lean

A workplace organisation method built around five steps: Sort, Set in order, Shine, Standardise, and Sustain. Used to create clean, organised, and efficient work areas where problems are easy to spot.

5 Whys

Lean

A root cause analysis technique. When a problem occurs, you ask “why” five times in succession to get past the symptoms and find the underlying cause.

A

Analytics dashboard

GembaDocs

The reporting view in GembaDocs that shows platform activity – including SOP views, user engagement, and team usage data.

Andon

Lean

A visual alert system used on the shop floor to signal that something needs attention — a quality issue, a safety concern, or a line stoppage. Operators trigger it, supervisors respond.

API access

GembaDocs

A technical connection that allows GembaDocs to share data with other software systems in your business, such as your ERP or HR platform.

Associate

GembaDocs

An operator or team member assigned to a skills matrix. Their competency levels are tracked against the tasks relevant to their role.

Audit trail

GembaDocs

A timestamped log of who created, edited, viewed, or approved a document. Used for compliance, quality audits, and incident investigation.

B

Bulk upload

GembaDocs

Adding multiple items — kanban cards, associates, or SOPs — to the platform in one action rather than one by one. Saves time when setting up at scale.

C

Chrome extension

GembaDocs

A GembaDocs browser tool that lets you capture video directly from your screen or camera to build a video step-by-step SOP without leaving your workflow. [view lesson]

Competency level

GembaDocs

A rating that indicates how capable an associate is at a specific task — typically ranging from untrained through to able to train others.

Continuous improvement (CI)

Lean

The ongoing effort to make small, incremental improvements to processes, quality, and efficiency. The foundation of lean thinking — no process is ever finished.

Cycle time

Lean

The time it takes to complete one unit of work from start to finish. Reducing cycle time without reducing quality is a core goal of lean operations.

D

Document approval workflow

GembaDocs

A structured sign-off process that requires one or more reviewers to approve an SOP before it goes live. Used in regulated industries to maintain document control. [view lesson]

E

Error proofing (Poka-yoke)

Lean

Designing a process or tool so that mistakes are impossible or immediately obvious. The goal is to catch defects at the source rather than downstream.

F

Flow

Lean

The smooth, uninterrupted movement of work through a process. Lean aims to eliminate anything that causes work to stop, wait, or pile up.

G

Gemba

Lean

Japanese for “the real place” — meaning the shop floor or wherever work actually happens. In lean, going to the gemba means observing processes directly rather than relying on reports.

Gemba walk

Lean

A structured visit to the shop floor by a manager or leader to observe work, identify waste, and engage with the people doing the job. Not an inspection — a learning exercise.

Global settings

GembaDocs

Platform-wide configuration options that apply across your whole GembaDocs account — including branding, permissions, and default document settings. [view lessons]

Green card

GembaDocs

A card on a task board that sits face up to show a job or SOP task is complete. When the card is turned over to red, it signals the task still needs doing. At a glance, your team can see exactly what’s been finished and what hasn’t. [view lesson]

H

Heijunka

Lean

Production levelling. Spreading work evenly across a time period to avoid peaks and troughs in demand on your team or equipment.

J

Jidoka

Lean

The principle of building quality checks into the process itself, so defects are caught immediately and the line stops before a bad product moves forward.

Just in time (JIT)

Lean

Producing or delivering exactly what is needed, when it is needed, in the amount needed. Reduces inventory waste and keeps material flowing through the process.

K

Kaizen

Lean

Japanese for “change for the better.” In lean, it refers to structured improvement events or a general culture of ongoing, incremental change driven by the people doing the work.

Kamishibai

Lean

A visual audit tool used in lean manufacturing. Cards are flipped daily or weekly to confirm that standard work and routines are being followed on the shop floor. Red side means not completed, green side means done.

Kanban

Both

A visual system for managing inventory and workflow. Cards represent items or tasks — when a card moves, something has happened on the floor. [view track]

L

Lead time

Lean

The total time from when a customer places an order to when they receive it. Lean focuses on reducing lead time by eliminating delays and non-value-adding steps.

Lean

Lean

A production philosophy focused on delivering value to the customer while eliminating waste. Originated from the Toyota Production System and now used across industries worldwide.

Lean Cave

Both

A dedicated space in for lean thinking resources — tools, templates, and references to support continuous improvement on the shop floor.

M

Muda

Lean

Japanese for waste. In lean, muda refers to any activity that consumes time or resources without adding value for the customer. There are eight recognised types.

Mura

Lean

Japanese for unevenness or inconsistency in a process. Mura leads to muda — uneven flow creates waste upstream and downstream.

Muri

Lean

Japanese for overburden — pushing people or equipment beyond their reasonable capacity. Leads to errors, breakdowns, and burnout.

O

OEE (Overall Equipment Effectiveness)

Lean

A measure of how effectively a machine or production line is being used, combining availability, performance, and quality into a single percentage score.

P

Point of work

Both

The physical location where a task is carried out. SOPs and instructions are most effective when accessible at the point of work, not back at a desk.

Pull system

Lean

A method where work or materials are only produced or moved when the next step in the process requests them. Prevents overproduction and reduces inventory buildup.

Push system

Lean

A method where work is produced based on a schedule or forecast and pushed to the next stage regardless of whether it is needed. Often leads to excess inventory and bottlenecks.

Q

QR code deployment

GembaDocs

Publishing an SOP so it can be accessed by scanning a QR code on a machine, workstation, or product. Gets the right information to the right place at the point of work. [view lesson]

R

Red card

GembaDocs

A card on a task board that sits face up to show a job or SOP task still needs to be completed. When the work is done, the operator turns the card over to green. The red side facing up is the prompt – something here needs attention. [view lesson]

S

Skills matrix

Both

A grid that shows which operators are trained, competent, or qualified in each task or process. Gives managers a clear view of team capability and training gaps.

SMED

Lean

Single Minute Exchange of Die. A lean technique for reducing changeover time – the time it takes to switch a machine or process from one product to another. The goal is to get changeovers under ten minutes.

Standard Operating Procedure (SOP)

Both

A documented, step-by-step instruction that tells an operator exactly how to carry out a task the right way, every time. [view track]

SOP folder

GembaDocs

A way to organise your SOPs within GembaDocs by area, department, process, or product line. Keeps your document library navigable as it grows.

Standard work

Both

The agreed best method for completing a task at a given point in time. SOPs are how you capture and share standard work across your team.

T

Takt time

Lean

The rate at which a product must be completed to meet customer demand. If your takt time is 60 seconds, you need to finish one unit every 60 seconds to keep pace.

Total Productive Maintenance (TPM)

Lean

A lean approach to equipment maintenance that involves operators in keeping machines running reliably. Focuses on preventing breakdowns before they happen.

Toyota Production System (TPS)

Lean

The manufacturing philosophy developed by Toyota that forms the foundation of modern lean thinking. Built on the pillars of just in time and jidoka.

V

Value stream

Lean

The full sequence of steps – both value-adding and non-value-adding – required to deliver a product or service to the customer.

Video SOP

GembaDocs

An SOP that uses video footage — recorded on a phone or via the Chrome extension — to show operators how a task is done, rather than describing it in text. [view track]

Visual management

Lean

Using visual cues — boards, signs, colour coding, floor markings — to make the status of work, equipment, and processes immediately obvious to anyone on the floor.

W

Waste (8 types)

Lean

The eight categories of non-value-adding activity in lean: overproduction, waiting, unnecessary transport, over-processing, excess inventory, unnecessary motion, defects, and unused talent.