Black Belt Exam Questions Flashcards
1
Q
The purpose of the Define phase of the six sigma methodology is to reach agreement on the scope and performance goals of a project. The deliverables of the Define phase include all of the following EXCEPT?
a. A data collection plan
b. A completed project charter
c. A high level process map
d. Completed project plans
A
a. A data collection plan
2
Q
A SIPOC map will help identify all of the following EXCEPT?^
a. Process
b. Suppliers
c. Inputs
d. Observations
A
d. Observations
3
Q
Which flowchart and value stream symbols represents a decision?
A
(Square rotated 45degrees)
4
Q
Financial criteria are often used by executive management and project champions to determine whether to undergo a project in terms of costs of the project and benefits to the organisation. This is commonly called the?
a. Return on Investment (ROI)
b. Project Activation Point (PAP)
c. Value Analysis
d. Project Cost Modeling
A
a. Return on Investment (ROI)
5
Q
The Voice of Customer will determine what improvements are desired and need to be made. All improvements are done with the goal of increasing the quality of the business output. The three key input components of quality are listed below which one of the choices below is incorrect?
a. The Customer
b. The employee
c. The value stream
d. The process
A
c. The value stream
6
Q
The ______ principle states that 20 percent of inputs result in 80 percent of outputs.
a. Taguchi
b. Pareto
c. Deming
d. Juran
A
b. Pareto
7
Q
Which process improvement diagram, picture, or chart would a greenbelt use to show if the improvements implemented in a project are improving from the baseline or benchmark?
a. Pareto diagrams
b. Scatter diagrams
c. Histograms
d. Trend analyses
A
d. Trend analyses
8
Q
The scatter diagram graphs pairs of numerical data with one variable on each axis to look for a relationship between them. If the variables are correlated, the points will fall along a line or curve. The better correlation, the tighter the points will be to the correlation line. Which of the following is NOT an application for a scatter diagram?
a. When you are trying to identify potential root causes of problems.
b. When you know two variables are related
c. When you have paired numerical data
When your dependent variable may have multiple values for each value of your independent variable
A
b. When you know two variables are related
9
Q
In Quality ERA 3 quality assurance and good manufacturing practices are instituted. In this step products are designed, quality is built into the manufacturing steps. The manufacture is controlled, tested, and rejects discarded. The result is fewer product rejects due to manufacturing. Which timeframe was quality ERA 3?
a. 1950s to 1960s
b. 1920s to 1930s
c. 2000 to present
d. 1980 to 1990
A
a. 1950s to 1960s
10
Q
The sigma symbol represents standard deviations from the normal range in a business process. The more deviation, the less desirable a product is. A Six Sigma business process is a process in which defective parts per million opportunities (DPMO) are determined and refined. Which level of sigma results in 66.807 defective parts per million?
a. 2nd Sigma level
b. 6th Sigma level
c. 3rd Sigma level
d. 4th Sigma level
A
c. 3rd Sigma level
11
Q
Which stage of team development is represented by team members becoming more comfortable and beginning to express their differences in opinion?
a. Forming
b. Storming
c. Norming
d. Performing
A
b. Storming
12
Q
Which of the following responsibilities or duties would be aligned with those of a six sigma green belt?
a. Executing the actual work of the project through guidance provided from six sigma green belts and six sigma black belts
b. Responsible for sponsoring the project and allowing for commitment of organisation resources to the six sigma project
c. Responsible for providing guidance and coaching others in the organisation about the six sigma philosophy.
d. Perform the operations required for the six sigma project and work with the project team ensuring that appropriate deliverables are met.
A
d. Perform the operations required for the six sigma project and work with the project team ensuring that appropriate deliverables are met.
13
Q
The measure of central tendency where half the values are greater than or equal to it and half are less than or equal to it is?
a. The mean
b. The mode
c. The median
d. The average
A
c. The median
14
Q
Which measurement data scale would include measures such as height ages, weight or length?
a. Nominal
b. Ordinal
c. Interval
d. Ratio
A
d. Ratio
15
Q
A Measurement System Analysis (MSA) is a designed experiment that seeks to identify the components of variation in the measurement. A Measurement Systems Analysis evaluates the test method, measuring instruments, and the entire process of obtaining measurements to ensure the integrity of data. Which of the following is NOT considered in a Measurement Systems Analysis?
a. Selecting the correct measurement and approach
b. Assessing procedures & operators
c. Determine the design of experiments
d. Assessing the measure device
A
c. Determine the design of experiments
16
Q
Which of the following descriptions of process capability is NOT correct?
a. Process Capability is a simple and straightfrowarde indicator of process capability
b. The more relaxed and widre the distribution the higher the Process Capability
c. Process Capability is a process index that numerically describes variation relative to the tolerance or specifications.
d. Process Capability is a short term process index that numerically describes the within subgroup or potential capability of a process assuming it was analysed and stays in control.
A
b. The more relaxed and widre the distribution the higher the Process Capability
17
Q
The cost of poor quality is measured differently depending on the industry. The first goal is to have all the cost of quality in the Appraisal and Prevention areas and zero Costs of Poor Quality. Which of the following is NOT an example of an external cost?
a. Complaints
b. Environmental costs
c. Warranties
d. Delivery
A
d. Delivery
18
Q
In correlation analysis the strength and direction of a correlation are defined and measured by its correlation coefficient (r). Values for correlation include all of the following EXCEPT?
a. 0 indicated absolute correlation
b. 0 indicates no correlation
c. -1 indicates a perfect negative correlation
d. 1 indicates a perfect positive correlation
A
a. 0 indicated absolute correlation
19
Q
Critical to Quality (CTQs) are the internal critical quality parameters developed around what the customer wants and needs. Three of the following are process parameters that affect CTQ measures. Which one is NOT a process parameter that affects CTQ measures?
a. Internal procedural disagreement in measuring and monitoring tools
b. The timing ratio computed by dividing the time remaining until due date by the work time remaining
c. Noise caused by internal environments as a result of neighbouring subsystems such as part to part or piece to piece variation
d. Controllable parameters which deal with a product feature or process step that mus be controlled to guarantee delivery of what the customer wants
A
b. The timing ratio computed by dividing the time remaining until due date by the work time remaining
20
Q
Failure Mode and Effects Analysis FMEAs are a systematic way of identifying and preventing problems before they occur and a proactive performance improvement tool to assist in new service design or existing processes. Failure modes determine the ways, or modes, in which something might fail. The effects analysis part of an FMEA studies what?
a. The improvement tools to be used.
b. Which effects are included
c. Which mode fails
d. The consequences of the failures
A
d. The consequences of the failures
21
Q
Poka Yoke is a concept in quality that means mistake proofing and can eliminate operator errors, measurement errors or supplier errors. Which of the following processes is NOT an exampple of Poka Yoke application?
a. Developing a standard operating procedure for painters on an assembly line
b. Preventing setup errors such as using the wrong tooling or setting machine adjustments incorrectly
c. Advancing the speed of a frozen dinner assembly line
d. Prohibiting wrong parts used in the process
A
c. Advancing the speed of a frozen dinner assembly line
22
Q
If a CEO were asking why printing costs are costing so much for a company and as the greenbelt you had reviewed paper costs, electricity costs, internal delivery costs, equipment rental costs, employee production costs which would be the most effective means of validating information?
a. Using project charter
b. Using control charts and process charts
c. Using the 5S method
d. Using a customer satisfaction survey
A
b. Using control charts and process charts
23
Q
Special cause variation is found through process analysis, control charts or process documentation. Special cause variation is variability or variation that triggers an essential change that is needed. Which of the following may cause special cause variation?
a. You adequately foresee common cause variation
b. You don’t identify an important variable
c. Natural variation is understood
d. Common cause variation is eliminated
A
b. You don’t identify an important variable
24
Q
There are many DPMO charts available to quantify defects analytically. If there are 4.261 defects per million opportunities, then the sigma level would be?
a. Closest to 2 sigma
b. Closest to 3 sigma
c. Closest to 4 sigma
d. Closest to 5 sigma
A
c. Closest to 4 sigma
25
The project plan template is a warehouse of information on how to improve the process. It outlines pilot studies and small scale tests of proposed solutions. The project charter does all of the following EXCEP?
a. Justifies the project efforts with financial impact
b. Defines roles of team members
c. Describes the problem and scope
d. Lists the tools to be used for the DMAIC
d. Lists the tools to be used for the DMAIC
26
Prototyping is the process of building a working model called a prototype to test various aspects of a design, changer or incorporate new ideas or improvements and react quickly to customer feedback at the improved product before implementing it on a large scale. What is the main function of prototyping?
a. Determine project costs
b. Determine customer needs
c. Reduces project risk and cost
d. Determine needed quality tests
c. Reduces project risk and cost
27
Walter Shewhart developed control charts in 1929 understanding variation had significant impact on quality. Which control chart is used to plot the mean and standard deviation of a subgroup more than than 5?
a. U chart
b. X bar-s chart
c. X bar-R chart
d. X-R chart
b. X bar-s chart
28
In which application would a Spearman Rank Correlation coefficient be used?
a. A measure that determines equality of sample medians
b. A measure that calculates r and allows the user to calculate partial correlation coefficient
c. A measure that requires both variables be measured on an ordinal scale
d. A measure that determines the degree of association among classifications of ranked scores
c. A measure that requires both variables be measured on an ordinal scale
29
In an FMEA the risk priority number is calculated by multiplying what?
a. Severity, Ocurrence and Detection
b. Risk, Opportunity, Options
c. Severity, Opportunity, Ocurrence
d. Causation, Determination, Prevention
a. Severity, Ocurrence and Detection
30
The analysis tool used to quantify the relationship between causes and effects would be?
a. FMEA
b. Multi variant analysis
c. Cause and Effect analysis
d. Regression analysis
d. Regression analysis
31
This formula denotes which process performance measure?
(Upper Specification Limit - Lower Specification Limit) / (6 x Process Standard Deviation)
a. Cp
b. Cpu
c. Cpl
d. Cpk
a. Cp
32
Considering confidence intervals, which of the following is correct?
a. The width of the confidence interval increases as the population sample size increases
b. A 90% confidence level will be wider than a 95% confidence interval
c. The width of the confidence interval will increase as the population size decreases
d. The width of the confidence interval decreases as the sample size increases
d. The width of the confidence interval decreases as the sample size increases
33
Which of the following is NOT an indication of an out-of-control signal in a control chart using a sample of approximately 20?
a. A run of four in a row are on the same side of the centerline
b. Two out of three successive points are on the same side of the centerline and farther than 2 sigma from it
c. Four out of five successive points are on the same side of the centerline and farther than 1 sigma from it
d. A single point outside the control limits
a. A run of four in a row are on the same side of the centerline
34
Variation is a change in data, characteristic, or function caused by one of four factors. Which of the following is NOT one of the four factors causing variation?
a. Special causes
b. Tampering
c. Common causes
d. Social variation
d. Social variation
35
The method for keeping a process within boundaries or the act of minimising the variation of a process is called the?
a. Process control
b. Process capability
c. Process capability index
d. Probability
a. Process control
36
Which set of Internation Standards Organization (ISO) standards covers quality management and quality assurance?
a. ISO 9001
b. ISO 1400
c. ISO 6000
d. ISO 1423
a. ISO 9001
37
Which of the following elements is NOT included in the cost of quality or the costs associated with providing poor quality product or service?
a. External Failure Cost
b. Internal Failure Cost
c. Recycle Cost
d. Inspection (appraisal) Cost
c. Recycle Cost
38
The Pareto principle defined by J.M. Juran states that most effects come from relatively few causes. It shows _____ of the effects come from _____ of the possible causes.
a. All, a sample proportion
b. 10%, 90%
c. 20%, 80%
d. 80%, 20%
d. 80%, 20%
39
A quality tool used for collecting and analysing data on the frequency or patterns of events, problems, defects, defect location, defect causes, particularly in production processes is the?
a. Check sheet
b. Scatter diagram
c. Control chart
d. Histogram
a. Check sheet
40
The six sigma tool used to improve a teams creativity and thinking, developed by Jiro Kawakita, which organizes a large number of ideas into their natural relationships is the?
a. Matrix diagram
b. Cause-and-effect/Ishikawa/fishbone diagram
c. Box and whisker plot
d. Affinity diagram
d. Affinity diagram
41
Which phase of the DMAIC model includes determining where problems or defects occur?
a. Define
b. Measure
c. Analyse
d. Improve
c. Analyse
42
Which of the following is a japanes management philosophy used to increase time between failure (MTBF) or life of machinery?
a. TOC
b. VOC
c. CTR
d. TPM
d. TPM
43
Simple linear regression is used when y is continuous and a single x variable exists. The following conditions must also be met EXCEPT?
a. The residuals are normally distributed
b. X can be ordinal or continuous
c. The residuals have constant variance across all values of X
d. The residuals are dependent
d. The residuals are dependent
44
Which of the following represents the number of defects divided by the number of products?
a. QFD
b. DPU
c. DPMO
d. COPQ
b. DPU
45
Which of the following is NOT a tool used in determining the project scope?
a. Product analysis
b. Data collection plan
c. Alternatives identification
d. Stakeholder analysis
b. Data collection plan
46
A type of bar chart that illustrates a project schedule with start and finish dates of the terminal elements and summary elements of a project including the work breakdown structure and the dependency of relationships between activities would be the?
a. DFSS chart
b. House of Quality
c. PERT chart
d. Gantt chart
d. Gantt chart
47
What is Mr. Henry Gantt famous for?
The high level project planning
48
What is the purpose of a SIPOC?
To identify the customers of our Process Output
49
What should you not show in your Project Charter?
The Stakeholder Map
50
Mention 3 good reasons for using a 'swim lane' flow chart?
...to make clear the responsibilities in the process
...to highlight the interfaces (handover points)
...to see clearly the critiques and issues
51
Which company invented the term 'Six Sigma'?
Motorola
52
What is the big difference between a LSL and a LCL?
VOC (min. spec.) and VOP (min. standard deviation)
53
Why should you have a 'milestone meeting' at the end of 'Improve'?
It is really to get the Go-No Go decision from the Sponsor/Budget holder, in order to continue with the implementation.
54
What is a Key Output Measure?
An quantitative output measure (ex.: parts produced)
54
Who invented ''Normal Distribution''?
Abraham de Moivre, in 1700 (before Mr. Gausse) a statistician and consultant to gamblers
55
What steps do you take with CTQ?
IGAD
...Identify
...Gather
...Analyse
...Define
56
What is the difference between Continuous and Discrete data?
Attribute data can not be divided in two, it's counted data
57
What is the difference between a Must Have & Delighter?
A delight is not expect and will not negatively impact the satisfaction.
58
What is the Stakeholders Map used for?
To develop a communication plan
59
What are the 7 wastes?
TIM WOODS
...Transport
...Inventory
...Motion
...Waiting
...Overproduction
...Overprocessing
...Defects
60
What is the main reason why people resist to change?
Not knowing, Not Able, Not willing
61
When creating a Value Stream Map (VSM), where is the place to start first?
Understanding the customer requirements
62
What is Takt time?
Takt time is the pace at which the process should operate to ensure the customer demand can be achieved
63
Who is TIM WOOD?
The 7 Wastes
64
What are the criteria for for a solid BB project?
...Improvement of 20% OTOWOCD
...Financial Benefit of at least 150k€ per year
...Increase Customer Confidence
...To run the project within 6-8 months
...Work with a Project Team
...To be able to use Lean Six Sigma
65
What means Kaizen (in English)?
KAI - Change
ZEN - Good
To change for the better
66
What are the 4 emotional phases that teams go through during DEFINE?
Forming, Storming, Norming and Performing
67
What is the big difference between 'Value Add' and 'Non Value Add'
VA = customer is willing to pay for
NVA = customer is not willing to pay for
68
What do the letters DMAICR stand for?
...Define
...Measure
...Analyse
...Improve
...Control
...Reinforce
69
What are 2 different types of Process Mapping?
...Swim Lane Flow Chart
...Value Stream Map
70
What is actually CTQ?
VOC made measurable
71
What is the purpose of the Kano Model?
To show relation between customers need vs satisfaction
72
Why do we use SMART?
It is a tool to make the project objective measurable
73
What is the purpose of Statistical Process Control (SPC)?
...To monitor, control and improve process performance over time by reducing variation at is source
...To distinguish between common and special cause variation
...Serve as a tool for ongoing control during the Control phase
74
What are the first 2 steps in translating the VOC into a CTQ?
...Identify (SIPOC)
...Gather / Collect (Interviews)
75
What is the difference between common and special variation?
The non-random variation within a process as a result of an action or an event
76
What does 'in control' mean?
In control means the process is consistent without special causes.
77
Name 3 definitions of Sigma?
...Standard deviation
...A management philosophy
...A process capability metric
78
What are the properties of the normal distribution?
...Bell shaped
...Symmetrical
...Uni-modal
79
Why is assessing for a normal distribution important?
...It allows evaluation of unusual distributions and potential root causes
...It is a pre-requisite test to calculate your process capability
80
Name four basic graphical analysis tools and their purpose?
... Pareto Chart - Prioritise focus based on 80/20 rule (scope project)
... Run Chart - Evaluate trends over time
... Histogram - Evaluate the shape of the distribution
... Boxplot - Compare multiple distributions for accuracy & precision
81
Which statistical tools evaluate relationships between variables?
...Scatter Plot - Graphically represent the relationship between 2 variables
... Correlation - Quantify the strength of the relationship
82
What does Kaizen mean?
It is Japanese for continuous improvement
83
What was the original use of the Drekker building (est. 1880)?
...Locomotive repair shop
...Foundry
84
What is Poka Yoke?
Error proofing is a technique for eliminating errors
85
What is the standard workflow chart (also know as a spaghetti chart)?
The standard workflow chart graphically represents the equipment layout with movement of materials and workers during the process. Route the way - people, material, documents, etc
86
What is the big difference between a Run Chart and a Control Chart?
The Control Limits
87
What is a Pareto Chart used for?
Prioritise focus (based on the 80/20 rule)
88
What is a fishbone diagram?
A visual representation of all the potential causes & their effect
89
What tool can be used to analyse to the lowest level root cause?
5 Why
90
What are the most important guidelines for brainstorming?
...No Criticism or Judgement
...First Quantity then Quality
91
What are Shingo Shigeo's four error-proofing steps?
...Elimination
...Flagging
...Facilitation
....Mitigation
92
Mention at least 3 'need to have' that an Black Belt Project should provide?
...To show that demanding objectives were met with customer and/or business benefits
...The use of a systematic methodology
...The use of appropriate improvement tools
...The ability to work well in a team environment
...Evidence that the candidate promoted improvement through coaching/training others
93
What is FMEA?
FMEA, or Failure Mode and Effects Analysis, is a systematic process used to identify potential failure modes in a system, product, or process, and their causes and effects
94
What is Kaoru Ishikawa famous for?
Fishbone Diagram / Cause-and-Effect Diagrama / Ishikawa Diagram
95
What are (3) attribute data process capability metrics (KPIs)?
% defective, DPU, DPMO
96
What is the purpose of Measurement Systems Analysis
To ensure that the data collected is a true representation of process variation (i.e. measurement system variation is small in comparison to process variation)
97
Define repeatability & reproductibility
...Repeatability is the variation when one person repeatedly measures the same unit with the same measuring equipment (within variation)
...Reproducibility is the variation when two or more people measure different units with the same measuring equipment (between variation)
98
What is Sigma?
...Standard deviation
...A management philosophy to improve quality
...A process capability metric
99
What is rolled throughput yield?
The probability of good output in multi step processes
100
What are the two types of data? Provide examples
...Attributive - Data that is counted
...Variable - Data that is measured
101
What is an operational definition?
Descriptions written in a way that ensures everybody understands
102
What other elements need to be considered when planning for data collection?
...Data stratification
...Training
...Sampling
103
What do we use the problem statement for?
To sell our problem to executive management
104
What do you need in case you step in the elevator with the CEO?
60 second elevator pitch
105
What are the belt colors?
...White Belt
...Yellow Belt
...Green Belt
...Black Belt
...Executive Black Belt
...Silver Belt
...Master Black Belt
106
What is the meaning of LEAN?
To Reduce Waste
107
What is the meaning of SIX SIGMA?
To Reduce Variation
108
What does PDCA stand for?
Plan, Do, Check, Act
109
How many % of mistakes are allowed in the BB exam?
30%
110
Ways to measure Accuracy & Precision
Accuracy:
...Mean
...Median
...Mode
Precision:
...Range
...Standard Deviation
111
What are the two types of variation?
...Common Causes
...Special Causes
112
What is 'TIM WOODS' used for and in which phase is it used?
...To make sure we never forget Waste
...Define
113
What is 'TEAM BUILDING' used for and in which phase is it used?
...To bring the team together
...Define but also all others
114
What is 'IS / IS NOT' used for and in which phase is it used?
...To not make the project too big
...Define
115
What is 'KANO' used for and in which phase is it used?
...To discuss the relation between Customer Need and Satisfaction
...Define
116
What is 'SMART' used for and in which phase is it used?
...To make the project goal measurable
...Define
117
What is 'SIPOC' used for and in which phase is it used?
...To Identify the customers of the process
...Define
118
What is 'Stakeholder Map' used for and in which phase is it used?
...To create a communication plan
...Define
119
What is 'Project Plan / Gantt' used for and in which phase is it used?
...To get the commitment of the team and sponsor
...Define
120
What is 'Flowchart / Swimlane' used for and in which phase is it used?
...To visualise the responsibilities
...Measure
121
What is 'GO / NO GO' used for and in which phase is it used?
...To make sponsor accountable
...All phases
122
What is 'HISTOGRAM' used for and in which phase is it used?
...To see if the process is normally distributed or not
...Measure
123
What is 'Moments of Truth' used for and in which phase is it used?
...To find out where customer is touch our process
...Analyse
124
What is 'Pareto' used for and in which phase is it used?
...To prioritise
...Analyse
125
What is 'Runchart' used for and in which phase is it used?
...To see a trend and to set a baseline
...Measure
126
What is 'Ishikawa' used for and in which phase is it used?
A communication tool to facilitate a root cause brainstorming Workshop
127
Why do we celebrate?
We celebrate to ensure people will join again
128
Why do we use the 5Why?
To get to the real root cause
129
What is the 8th waste?
Under utilisation of people
130
Which statistical tools evaluate relationships between variables to ensure that the data collected is a true representation (...)
Question incomplete
131
What is the Process of Statistical Process Control (SPC)?
...Monitor our process with number
...Distinguish common cause and special cause
...Control of the execution phase
132
How are Control Limits different from Specification Limits?
...Control limits are calculated by Data (VOP - Voice of Process)
...Specification limits are calculated by Customer need (VOC - Voice of Customer)
133
What does 'In Control' mean?
Process is consistent without special causes
134
What is Sigma?
... Standard deviation
... A management philosophy to improve quality
... A process capability metric
135
What is rolled throughput yield?
The probability of a good output in multi-step process
136
What are 2 types of data?
Attributive - data we can count
Variable - data we can measure
137
What is an operational definition?
Everybody understands the same thing
138
Big difference between Lean and Six Sigma project?
Six Sigma: to reduce variation
Lean: to reduce waste
139
How are control limits different to specification limits?
VOP - calculated
VOC - given
140
What is the big difference between a LSL and a LCL?
VOC (min. spec) and VOP (min. standard deviation)
141
What is the first question to ask when starting a statistical analysis?
Is the data normal?
142
What is the difference between common cause and special variation?
The non-random variation within a process as a result of an action or an event.
143
When creating a value stream map, where is the place to start first?
Understanding the customer requirements.
144
What is TAKT time?
The pace at which the process should operate to ensure the customer demand can be achieved.
145
What is the Kano model?
Matrix of customer needs vs customer satisfaction
146
What is the 5M related to?
Ishikawa
...The 5 M is a traditional framework to classify the possible causes of a problem.
...The 5 kind of causes are: Material, Machine, Manpower, Method, Milieu (French word for Environment).
...Sometimes we speak about 6 M, with addition of the Measurement (used in SPC and Six Sigma projects).
147
What is the 5S related to?
Five related terms, describing workplace practices to organize and improve efficiency of work.
148
What is the 5 WHY's tool?
It consist on asking 5 times "Why" in order to discover the root causes of a problem.
149
What is the 7 MUDA concept?
7 MUDA (or 7 Wastes). MUDA is a Japanese word that means "waste", the 7 MUDAs helps us identify "waste" from the customer perspective and then determine how to eliminate it.
The 7 MUDAs are:
Muda 1: Overproduction
Muda 2: Waiting Time
Muda 3: Transport, Handling
Muda 4: Unnecessary operation
Muda 5: Stock and buffer
Muda 6: Unnecessary movement
Muda 7: Rework and repair
150
What does Andon refers to?
A visual management tool that displays the status of operations with appropriate lighting and different colours. For example, an Andon can also display production status (which machines are operating) or abnormality (like machine downtime, a quality problem, materials shortages or operator delays) and need actions.
Exaples; A typical Andon is an overhead signboard.
151
What does creating a balanced flow entail?
Smoothing the workload and variety of throughput so that the total available resources are applied consistently, avoiding overloaded or underused resources when performing the activities of a value stream.
152
What does the concept "Buffer" stands for?
Products waiting in the production process. Buffers are included in the WIP (Work in Progress) and so in the lead time.
153
What does the concept "Build to Order" stands for?
"Build to Order" (BTO), or "Make to Order (MTO)", is a production approach where once a confirmed order for products is received, products are built. BTO is the most appropriate approach for highly customised or low volume products.
This approach is considered good for highly configured products, e.g. computer servers, or for products where holding inventories is very expensive, e.g. aircrafts.
154
What does the concept "Build to Stock" stands for?
"Build to Stock (BTS)", or "Make to Stock (MTS)", or "Build to Forecast (BTF)" is a build ahead production method in which production plans are developed based on historical demand information in combination with sales forecast information.
This approach is considered good for high volume and cheap products where the demand is either seasonal or easily predicted, or both.
155
What is Continuous Flow Production?
Alternatively called "one - piece flow", "single - piece flow", "make one, move one".
Producing and moving an item or batch at a time by using a series of Lean as continuously as possible. Each step makes only what is required by the next step, thus preventing bottlenecks.
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What is Cycle Time?
The time it takes to complete a part or product by a process, as timed by observation.
This means, the time it takes an operator to go through all work elements before repeating them. Also it can be referred as touch time or hands-on time, such as "Machine Cycle Time", "Operator Cycle Time".
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What is FIFO?
First In - First Out
Is a method based on keeping exact production and delivery sequences by ensuring that products "enter" and "leave" the processing stations in the same order as they first enter the system.
FIFO is an important condition for pull system implementation.
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What is a Flash 5 Meeting?
A 5 minute meeting at the beginning of every shift to discuss production results, quality concerns, production scheduling, and improvement ideas.
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What are flow racks (or flow-through-racks)?
Storage racks that use shelved (metal), equipped with rollers or wheels. Such a construction allows goods, products or materials to "flow" from the back of the rack to the front.
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What is FMEA?
Failure Mode & Effect Analysis
It is a procedure for analysis of potential failure modes within a system for the classification by severity or determination of the failure's effect upon the system.
It is widely used in the manufacturing industries in various phases of the product life cycle and is now increasingly finding use in the service industry as well.
Failure causes are any errors or defects in process, design, or item especially ones that affect the customer, and can be potential or actual. Effects analysis refers to studying the consequences of those failures.
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What is the Handbook?
The book which has been designed to help us to understand what Lean Six Sigma is really all about.
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What is Heijunka?
Japanese word, which means "levelling".
It aims levelling the variety and/or the volume of items over a fixed period of time. Heijunka is used to prevent excessive batching of product types and/or volume fluctuations and results in a minimum of inventories, capital costs, manpower, and production lead time above the whole value stream, mainly at a pace setter process.
Exemplary Heijunka production types are "mixed-model-production".
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What is Hoshin Workshop?
Hoshin is a japanese word which means "compass". The main focus is to search in the workshop, with the workers, simple and quickly applicable solutions to optimize flows and eliminate wastes.
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What is Inventory?
A cost component for the most businesses, comprised of all raw materials, purchased parts, work-in-process components, and finished goods that are not yet sold to a customer. Moreover inventory includes consumable goods, used in production
(Inventories = Stocks + WIP)
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What does the concept "Just in Sequence" stands for?
JIS (Just in Sequence) is a combination of "Just-in-Time" delivery with production line sequencing of delivered items.
A customer will notify a component supplier about needed items and the sequence of delivery based on the customer's manufacturing schedule, sometimes directly to the assembly line.
Most common is this in the automotive and similar assembly line industries, where each product on the assembly line can be configured differently.
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What does the concept "Just in Time" stands for?
JIT (Just in Time) is a production system to make and deliver just what the customer needs, just when the customer needs it and just in the amount needed.
In the Lean context JIT bases Heijunka as a foundation and includes 3 elements which make it possible:
- Pull system
- Takt time
- Flow production,
by using minimal resources of manpower, material, and machinery.
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What is Kanban?
Japanese word that means "label, ticker or card".
A Kanban system is an easy, transparent system to control logistics and production processes by signalling device that gives instruction for the production or withdrawal of items in a "pull system".
- To implement a pull system.
- To establish a self-regulating process (with equilibrium between processes).
- To be performed when the process is mature for an extended period of time.
- To have a defined range of material at the location of demand.
- To have a very simple supply process (e.g. Visual Management).
- To optimize operating costs of machining stations (batch production, setup sequences, tool changes).
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What is a KPI?
Key Performance Indicator
A vital measurement tool for showing how the business is performing, from shop floor, or Gemba level feeding right up into company targets and goals.
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Define Lead Time.
Customer Lead Time:
The time from when a request for a product is made until the product is ready to be shipped to a customer.
Manufacturing or Production Lead Time:
Through-put-time from shop floor order to completion including buffers.
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What is Lean?
An umbrella term for a powerful combination of principles, methods and tools to increase business performance. Lean is a term used for what was originally known as the "Toyota Production System". Lean was developed by Toyota to improve the performance of their manufacturing environment.
Lean is also a set of operating rules designed to identify activities that create value in an organisation and to eliminate those that produce wastes (MUDA).
Lean Productions is about doing more with less: less material, less time, less space, less human effort, less capital, etc.
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What is the Lean Booklet?
A small brochure for every employee's "trousers pocket" about the company's philosophy and the Lean Methods and Tools.
The sense is, that every employee - from the management down to the assembly operator - understands and internalizes the methods and tools.
A Lean Booklet is tailored for every company.
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What is a Lean Game?
A Lean Game is conceived to show Lean Production in practice.
It shows in successive rounds the way from a Push- to a Pull-System by using continuous improvement processes and in consideration of the Lean Principles, methods and tools.
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What is a Learning Cell?
In a "Learning Cell", a segment of the whole production process is selected and analyzed with the purpose of alowing its members to develop and improve assembly and logistics processes. An an ongoing improvement process, the learning cell is an area where it is allowed to make mistakes - as long as we learn by them.
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What is a Logistic Material Classes?
Logistic Material classes is a system to handle the material according to their optimal way of supply. By allocation of every part to one of the 4 Material Classes benefits are achieved in the physical supply as well as in the indirect logistics departments (disposition, storage...)
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What is a Manufacturing Lead Time?
Through-put-time from shop floor order to completion including buffers
See: Cycle Time
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What is a Marketplace?
The Marketplace is the first step of the assembly process by preparing the material to the assembly's demand. The preparation of material is to be understood as a process that requires a defined area. This area is defined by the parts for one helicopter; the material range of the Marketplace is determined by the customer demand rate.
See: Learning Cell, Visual Management, Takt-Wagons, Material Classes
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What is MIFA?
MIFA (Material and Information Flow Analysis), developed by Toyota, is a lean diagnostic tool to analyze material and information flows.
See: Value-Stream-Mapping, MIFD
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What is MIFD?
MIFD (Material and Information Flow Diagram) is a flow diagram that illustrates the flow of material among different processes and the required information to transform raw material and semi-finished goods into final products.
The diagram shows a complete overview and not individual stLean and so can be used to used to understand and improve the material and information flow processes overall.
Material and Information Flow Diagram can also be used to generate a basic understanding of the current state inside a project team.
See: Value-Stream-Mapping, MIFA
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What is Milkrun?
A method to speed the flow of materials between facilities by routing transport units to make multiple pick-ups and drop-offs at one tour. By making frequent pick-ups and drop-offs with milkrun vehicles connecting a number of facilities rather than a ''taxi transport'', it is possible to reduce inventories, empty tours of the transporter and response times along a value stream
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What is One Piece Flow?
Principle to transfer work between processes one piece at a time, in order to minimise WIP (Work in Progress) inventories and lead time, and to optimise soace,
It helps to detect quality problems quickly.
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What is Operating Stock?
Variable stock (or buffer) resulting from lot sizes, customer consumption, and frequency of supplying and picking.
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What is Order Lead Time?
The time the customer must wait for the product since he first placed the order. This includes the order processing time, the production lead time and the time expended downstream in getting the product to the customer. This means the elapsed time between the moment a customer decides to need a product and the moment of delivery.
See: Cycle Time
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What is Pace Setter?
A device or technique used to set the pace of production and hold the takt time. The pace setter process usually is found at the end of the value stream, often in the final assembly cell, but if the products flow from an upstream process to the end of the stream in a FIFO sequence, the pace setter may be a part of the whole upstream process.
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What is Pareto?
The Pareto principle known as the 80-20 rule states that 80% of thee effects come from 20% of the causes (problems, sales, defects, etc.).
A problem solving tool (a bar chart or graph, called ''Pareto Diagram'') showing the bars in descending order of significance from left to right. A Pareto Chart focuses on improvement activities of the ''vital few'' and not the trivial many.
See: FIFO, Heijunka
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What is a Poka Yoke?
Poka-Yoke is a Japanese word for ''fool proof'', alternatively called ''Mistake - Proofing'', ''Error - Proofing'', ''Fail - Safe'' and ''Baka - Yoke''.
Poka - Yoke devices are mechanisms that either prevent a mistake from being made or make mistakes obvious at a glance.
Defect parts are filtered out of the ongoing process and are prevented from being passed on to the next process step. This prevents further procession of faulty parts, damages to following process machines and therefore further MUDA.
Examples:
Countoured locators or templates
Proximity or photo-electric sensors
Limit or micro switches, warning lights or buzzers
Pressure transducers
Products designed in such a way that they eliminate installing parts in an incorrect form
See: 7 MUDA
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What is Production Lead Time (or Manufacturing Lead Time)?
Through-put-time from shop floor order to completion including buffers
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What is Pull System (or Pull Flow)?
A system that produces or delivers according to the real customer consumption, and stops the production if the consumption stops.
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What is Push System (or Push Flow)?
A system that produces or delivers according to a scheduled customer demand (production planning based on forecasts or historical consumption), regardless of the real customer consumption.
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What is Security Stock?
Stock (or buffer) set up to prevent downstream processes from being starved of goods because of problems at an upstream process.
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What is Setup Time (or Changeover Time)?
Time required to change a workstation or machine from producing one type of part to another type.
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What is SMED?
SMED (Single Minute Exchange of Die) is a method of changeover time reduction developed from 1950 to 1960 by Shigeo Singo.
See: SMED
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What is SMF (Synchronous Material Flow)?
Constant, permanent and synchronous material flow, normally in combination with ''Continuous Flow Production''
...Reduces inventories and lead times
...Improves material flow and control
...Enhances production flexibility
...Encourages effective utilization of people, equipment, space and energy
...Eliminates waste and minimizes non-value added activities
...Eliminates bottlenecks & improves throughput
See: Lean, Kanban
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What is Smoothing Stock?
This variable stock (or buffer) is the consequence of the gap between the real customer consumption (not smoothed) and the smoothed production plan of the supplier workshop or unit.
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What is SPC (Statistical Process Control)?
Statistical Process Control (SPC) is a production monitoring and quality improvement tool. It indicates if processes are running as they should or not. When employed fully, the data from SPC gives information on the state of the production process and hints on actions to regain control of the process.
The amount of measurements taken (sampling frequency) is matched to the stability of the process and can range from a few samples of the process each day to up to 100%.
The statistical analyses of the data show if the process is characterised by a normal Gauss distribution and give other key figures among which the mean value, the standard deviation and data range are the most importante. These ( often online) results give the worker a direct feedback to control the process and, if necessary, to make required adjustments before the process runs out of limits.
SPC control can be made easier to monitor through Visual Management methods like optical process control charts which have green, yellow and red limits. Detailed analyses show if the process has the necessary stability and capability.
See: Andon, Visual Management
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What is SQM (Self Quality Matrix)?
SQM is an effective tool to reach the self quality target:
To prevent defects from going further down the production sequence.
Ideally: Avoid defect creation
Total and definitive eradication of the defect root cause
At least: Detect the defect systematically and just after his creation
=> Avoid non quality from going to the next workstation
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What is Standardized Work?
Standardized Work is the most efficient combination of man, machine, and material based on the three elements:
...Takt time
...Work sequence
...Standard inventory or Work-in-Progress
See: Kaizen
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What is Stock?
Finished good entered in a SAP stock.
They are not included in the WIP and the manufacturing lead time calculation.
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What is Takt Time?
Conversation in time unit of the smoothed customer demand for one product to deliver (every how many minutes, hours or days needs the customer a product ?)
TAKT TIME (in time unit) = (Opening timer per period) / (Customer Need per period)
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What is Takt - Wagon?
It is a standardised supply wagon which is delivered to the production line according to Takt time. The Takt-Wagon is filled up with the necessary materials by the MArketplace according to the assembly process.
The arrangement of the material in the wagons is to be defined with the production. The Takt-Wagon supplies all materials and information necessary (documents, quality sheets...).
See: Marketplace
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What is TPM (Total Productive Maintenance)?
Total Productive Maintenance is a method to ensure optimal utilisation and output of production facilities and to prevent production interruptions, by focusing on preventing machine downtime and continuously improving machine liability and availability.
It focuses on:
...Involvement of all employees and areas, that is not only in the area of the operational facilities, but also in indirect areas that are concerned with these facilities. For example: production planning, purchase department, etc. and considerable management attention
...Inclusion of all elements of maintenance (preventive, planned, computer aided, etc.)
...Economic effectiveness on a total cost view
...Elimination of the 'Six Big Losses' (Breakdowns, Setup and Adjustments, Micro Stops, Non Quality, Missing Resources, Planned Stops)
...Autonomous maintenance
...Qualification and training
...Preventive maintenance
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What is Value Creating Time?
The time it takes to transform the product in a way that the customer is willing to pay for it.
Normally, ''Value Creating Time'' is less than ''Cycle Time'', which is less than ''Production Lead Time''.
See; Cycle Time, Production, Lead Time
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What is VSM (Value Stram Mapping)?
A simple diagram that shows every process step involved in the flow of material and information which requires a product from order to delivery.
See: MIFA, MIFD
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What is Visual Management Tools?
The easiest way to assimilate information is through the eyes!
...Using colours only where they have a specific purpose or function and translate precise information.
...Eliminating colours where they do not have specific purposes or functions.
...Process control through signs, boards, markings, visualisation of key figures, etc. that explicitly animate people to specific self controlled actions.
...Creation of standards to visualise abnormalities or deflections from normal situations within the entire plant.
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What is WIP (Work in Process)?
Work-In-Process consists of the unfinished products in a production process.
Finished products stocks are not included in the WIP.
See: Inventory
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What is WPS (Workshop Production Schedule)?
''WPS'' is the tool used in Lean to define and validate in a weekly meeting (featuring production, scheduling, supplying, quality, and all other support services involved) the smoothed production plan of the next weeks (generally five), in accordance with the customers needs and validated available resources: workers, inventories, machines, tools..
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What is Yamazumi?
''Yamazumi'' is a Japanes word which means ''pile'' our ''stack (up)''. A Yamazumi board is a bar graph showing the balance of workloads as operator cycle times. It can also be used for load planning and scheduling, taking a process and differentiate into value adding and non valuer adding activities.
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What is Zoning?
Using a standard system of colours to define different areas and types of material in the workshop.
