Analyze Phase Flashcards
What is the analyze phase?
What are the root causes?
Where do you get the problem statement for the Fishbone diagram?
The CTC or CTB questions
What are the 6 M’s in the Fishbone diagram?
Man, machine, method, material, measurement, mother nature
What is the purpose of the fish bone diagram?
To brainstorm possible root causes to your problem statement, and then cluster
What should you include for each of your possible root causes on your fish bone diagram?
Five why’s
What is the C in CNX?
Constant, can’t change
What is the N in CNX?
Noise, what impacts the environment
What is the X in CNX?
Number, the variable you can control
What is Tool 3 and where do you get the potential causes?
Root cause analysis, from the Fishbone diagram(Ishikawa)
What is a Gemba walk?
Study of where the action happens
What should you do in a Gemba walk?
Observe the environment as is
Communicate
Do not interfere
What is included in the Gemba table?
Defining the process
the hypothesis
define the measurement and data source
what are the conclusions?
What are the four process mapping types?
Flow chart
swim lane
spaghetti
value stream map
What is a flow chart?
Start and stop points that include process steps in its actual sequence
What is a swim lane diagram?
A process in which people who are involved in the process are identified, organized vertically, and marked with start and stop points to formulate process steps with a noun and verb. The process steps are arranged in actual sequence and marked for known waste points
What is a spaghetti diagram?
To identify the current motion of material products or people in a current process
What is a value stream map?
Used to identify sources of waste by mapping material flow, information flow, and other process relevant data or improvement potential to reduce process lead time
What are the three value analysis activities?
Value adding activities
value enabling activities
non-value, adding activities
What is value adding activities?
Is the customer willing to pay?
What is value enabling activities?
Is the business willing to pay?
What is non-value adding activities?
Waste
What are the types of waste or TIMWOODS?
Transport
Inventory
Motion
Waiting
Overproducing
Over processing
Defects
Skills
When do you do a time analysis?
Only when the CTC or CTB is time related
What do you do in a time analysis related problem?
Collect all relevant times for all process steps
What is PLT?
Process lead time, from start to finish
What is capacity?
The max output rate
What is capacity the result of?
Processing time and number of operators
How do you calculate capacity?
Unit
——-
Time
What is a bottleneck?
Process step with least capacity or throughput
What is a constraint?
Bottleneck that is not fulfilling customer request
What is throughput?
Produced units per given time as is
What is TAKTRATE?
Requested units per given time, to be
How do you find the TAKTRATE?
Requested number of parts
————————————-
given amount of time
What is the TAKTTIME?
Given time per requested units
How do you find the TAKTTIME?
Given an amount of time
———————————-
Requested number parts
What are potential constraints?
Process steps that might lead to not fulfilling the customer TAKT.
What is Little’s law?
PLT= work in progress/exit rate
What is lean focus?
A stabilizing process to reduce inventory and increase exit rate
What happens when you reduce work in progress?
The process leadtime decreases
What is process efficiency?
The need to identify improvement opportunity by comparison with industry and other benchmarks
How do you find the process efficiency?
Value adding time
————————— x 100%
process lead time
How do you find exit rate?
Pieces
———
time
What is data analysis/data stratification?
Splitting data according to different factors in order to find potential influencing factors
What are the 4 goals of the analyze phase at the gate review?
Potential causes collected
Analyze the process
Analyze the data
Derive main causes
What are the two verification doors that you need to choose between to verify your data in analyze phase?
Data
Process
