Analyze

Question 1

What is the question asked in the analyze phase?

Answer 1

What causes the problem?

Question 2

What does the tool 3 help us with?

Answer 2

It help us to prioritize the potential causes to further analyze

Question 3

What is the cause and effect diagram?

Answer 3

It’s the diagram, also known as Ishikawa diagram, and it is used to find the possible root causes a.k.a. Xs

Question 4

How does the cause and effect diagram work?

Answer 4

It is a holistic approach for a brainstorm, adding causes under different categories, using the 6 Ms

Question 5

What do the 6 Ms of the Ishikawa diagram stand for?

Answer 5

Man, Method(SOP or process), machine, measurement system, material and mother nature

Question 6

What do we do with the potential causes found in the Ishikawa diagram?

Answer 6

They are categorized by constant(C), noise(N) or variable(X)

Question 7

What is the end goal of the analyze phase?

Answer 7

To get the true root causes and go to the improve phase

Question 8

After categorizing, my causes found in the Ishikawa diagram as constant C, noise N or variable X. What do I do with them?

Answer 8

I take my Xs only and use Tool 3

Question 9

How can I verify if my causes are “true root causes”?

Answer 9

For the green belt, we will do a process analysis.
1. Gemba
2. process visualization
3. Value analysis
4. Identify waste

Question 10

How did you conduct a Gemba?

Answer 10

By physically, observing the process as it is happening
Tips: prioritize and set up a specific hypothesis (goal) prior gemba
Observed a specific process step (your point of interest)

Question 11

What are the tools used for process visualization?

Answer 11

Different charts, such as flow chart, swim lane diagram, spaghetti diagram and value stream map

Question 12

What tool is used to recognize waste?

Answer 12

TIM WOODS

Question 13

What do the letters of Tim Woods stand for?

Answer 13

Different different types of waste:
Transport
Inventory
Motion
Waiting
Over production
Over processing
Defect
Skills

Question 14

When shall you do a time analysis?

Answer 14

When you have a time related problem

Question 15

What does the process leadtime include?

Answer 15

Processing time + waiting + set up + transport, etc.

Question 16

What is a bottle neck?

Answer 16

It is the step within the process with the lowest capacity

Question 17

What is a constraint?

Answer 17

It is a bottleneck that is preventing from reaching the customer demand

Question 18

What is the exit rate or through put of a process?

Answer 18

It is the overall capacity of the process and it is the limited by the process step with the lowest capacity a.k.a. the bottleneck

Question 19

How to calculate TAKT rate

Answer 19

= (requested number of parts)/given a amount of time
This is where we want TO BE

Question 20

How to calculate TAKT TIME?

Answer 20

=(given amount of time)/(requested number of parts)

Question 21

What is little’s law?

Answer 21

It’s a formula that calculates the expected process lead time taking into consideration the work in process and the exit rate

PLT=(WIP # of parts)/(Exit Rate #parts/t)

Question 22

How can I determine my process efficiency? (PE)

Answer 22

PE=((value added activities time)/(total process lead time))*100

This Is a % NeedsTo Be multiplied By 100

Question 23

What is the problem with Little’s law?

Answer 23

It is only a Snapshot in time and if the process is not balanced, then we will not have the same results all the time

Question 24

What are the best conditions to apply little’s law?

Answer 24

A balanced process
The work in process is stable in = out
Fifo

Question 25

How is data stratification done?

Answer 25

split the data according to different factors, to find differences and indicators of the problem.
It helps you find potentially influential factors on my data

Question 26

What happens if the TAKT rate is > than the exit rate?

Answer 26

It means that we have a constraint