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brainscape LSS3 Flashcards

1
Q

DMAIC Overview

A

Use for persistent problems, have committed people, upward flow of ideas & team sprit, ownership of action, high-value projects.

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2
Q

When should you not use DMAIC?

A

Do not use if no specific problem , solution already known, no process.

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3
Q

Define: 11

A

Get 1)VOC, 2) VOB, 3) focus area, 4) validate project charter. 5) Project Charter: 6) Business Case, 7)Opportunity or problem statement, 8)goal state, 9)scope , 10)project plan, 11)team selection.

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4
Q

Measure: 9

A

1-Map process, 2-Kpov?s(y?s), 3-Calc PLT, 4-Data collection plan, 5-MSA plan, 6-Control Charts for process stability, 7-Process Capability, 8-Baseline,9- Quick improvements

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5
Q

Analyse :6

A

1) KPIV(x?s), 2)root cause analysis, 3)CE matrix, 4) failure modes and effects analysis(FMEA) 5)Hypothesis testing, main effects charts, 6)regression analysis

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6
Q

Improve 6

A

1)Critical x?s, 2)potential solutions, 3)select solution, 4)optimize solution, 5)pilot solution, 6)new process capability

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7
Q

Control 4:

A

1)Eliminate defects, 2)control plan, 3)final financial/process metrics, 4)document project for future implementations, transition to owners.

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8
Q

DEFINE Overview

A

: Identify problem, complete & validate charter. Get: VOC,VOB, CCR, CBR, Financial befits, final project focus, project Define gate review.

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9
Q

Project Charter:

A

1-define problem, 2-mission, 3-contract between sponsor and BB. 4-Living & iterative document. 5-Written by Sponsor, 6)deployment (owner) manager of process, controller, executive staff, BB & team.

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10
Q

Name a tool used in Project charter development

A

USE: RACI for charter development.

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11
Q

What is Scope?:

A

Start and end, authority, commandments, monuments, 80/20 to narrows scope.

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12
Q

differentiate types of benifts.

A

T1 $ saved, T2 Cost avoidance, T3 increased sales, effectiveness, T4-Compliance & feel good.

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13
Q

Define Benefits:

A

Baseline, changes, results of actions in $, Kaizen, Green or BB project?

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14
Q

Team:

A

% of time, SMART Goals: Specific, measurable, attainable, relevant(realistic), time bound

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15
Q

How does VOC relate to Project?:

A

Get product process design requirements.

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16
Q

How is SIPOC translated to hard numbers

A

. Translate VOC>CCR>KPOV(y?s)

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17
Q

how do you Validatesproblem statement?

A

VOC

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18
Q

How do you get VOC?

A

Use interview, survey, focus groups, complaints market share, returns, etc.

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19
Q

Ways to Segment customers?

A

Segment customers ($, Geo, product , industry, price, etc) Use: Customer Segment matrix, Use interview, survey, focus groups, complaints market share, returns, etc.

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20
Q

VOC>CCR means what?

A

go from general to specific.

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21
Q

Tools used in Define phase

A

Affinity Analysis, Tree diagrams, Kano Model (satisfiers/ spoken; dis/notspoken; delighters/notspoken), SIPOC

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22
Q

CCRs>KPOV become what?

A

Y=f(x1,x2,?xn) customer and businesess.

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23
Q

KPOV?

A

Big Y?s

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24
Q

SIPOC: tools

A

Uses C&E, Y?s & X?s, y=f(x),

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25
Q

Value Stream Mapping

A

, validates relationship between x & y, validates problem statement. No root cause nor solution in Problem statement.Validate with VOC & VOB

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26
Q

PROJECT MANAGEMENT Tools are used to

A

to balance scope, cost, time, requirements & customer expectations.

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27
Q

Name parts of project managment

A

define Roles, Triangle, Risk, Stakeholders,Communcation plan, team launch

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28
Q

What are the BB/PM Roles:

A

coordination, resource planning, organizing, leading, relationships, information, decision.

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29
Q

Triangle:

A

Time, cost, results (scope)(quality)

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30
Q

Risk:

A

identify, prioritization grid, ^Impact >Probability , Risk Response: Avoidance, transference(Insurance, warranty, guarantees) , mitigation, acceptance.

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31
Q

Stakeholders analysis?

A

Use: SH analysis matrix 1-5 resistance, passive R, Passive support Active S, strong S. Likelihood of support Matrix: 1-5

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32
Q

Communication Plan:

A

Audience & media Use: Action logs, Quad charts, status plan, RACI Chart

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33
Q

Teamlaunch:

A

Team, balance size,/skills,/social style,/mission, ground rules, RACI

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34
Q

Team Launch Deliverables

A

objective, goals, rules roles, responsibilities, draft project plan, roles and responsibilities, prework email, bring docs, 1-2 weeks ahead, mission, agenda, data commitment.

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35
Q

How do you organize ideas in team launch?

A

Affinitize ideas. Feadback: conflict, decisions, effectiveness. voting

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36
Q

Wrap up of project launch

A

: action items Summary: time, cost , quality, ongoing planning, sense ofurgncy, priorities, deliverables itemized, approval & sign off. PM/BB : plan, organize, implement, control

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37
Q

Discuss Variation & Common Cause

A

85-95% Wear, tem flux, material harness, experience, server response.

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38
Q

What is Tampering?

A

: over adjusting in response to noise=

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39
Q

What is Special cause?

A

other than common cause . Tools: run charts, control charts. 5-15% Special cause.

40
Q

What is included in Define Gate?

A

: identify risks, rsoruce utilization, capital, barriers, go/no go by sponser. Readyness checklist: SIPOC, VOC, CCR, Y?s: Cost, Quality, capacity, revenue, capital, data collection plan, benefits, project

41
Q

Measure

A

charter, team, PM, tollgate checklist to sponsor

42
Q

Types of Variability

A

: Accurcy, precison

43
Q

Accuracy:

A

average measure = true vale

44
Q

Bias :

A

difference between average and true

45
Q

Sources of Bias?

A

Sources are operator, instrument, other (site, temp, customer, supplier)

46
Q

What does Precision measure?:

A

Same results on same part

47
Q

What does Repeatability measure?

A

inherent variation same part, person instrument. Also called gage precsiosn.

48
Q

Reproduceablity

A

: variation by different operators using same tool

49
Q

What is the difference betweenPrecision & accuracy

A

precision is the repeatblity samepart same tool. Accurace is the true value or average measure

50
Q

What is Discrimination?

A

The ability of the tool to measure within your specifications

51
Q

What does the Measure phase include?

A

: 1-Value Stream Map/2-Kpi & KPO metrics/ 3Operational definitions/ 4data collection plan/ 5validate measurement system/ 6collect baseline data/ 7determine process capability/ 8 measure gate.

52
Q

Desccribe MSA

A

Variablity: Bias or instrument accuracy problems: clustered off center/Repeatability or Gage precisions issue:

53
Q

What is the most important deliverable of measure?

A

Value Stream Mapping :Top is info, middle is process, bottom is time

54
Q

8 forms of WASTE:

A

Time, inventory, motion, waiting, overproduction, overprocessing, defects/rework & People.

55
Q

Describe types of Data

A

Continous/ Discrete

56
Q

Name Data tools

A

Data measurement plan: Pareto, histogram, control chart, scatter diagram.

57
Q

What is Stratfication?

A

What, when, where, who? ( complaints, dates, city, dept) Not too many or too little. Use: check sheets, frequency plots Consider: time, cost accuracy.

58
Q

What is Inferential statistics?

A

Conclusions about population from sample.

59
Q

Talk about Samples:

A

Random, prevent bias, stratified random, between and within. Minimize within so you can see between sample variation.

60
Q

MSA: What are we measuring?

A

X= key process baseline. Y = Goal measure control. MSA for continuous data: Accuracy & Precision are most important in chart above.

61
Q

What is %RR?

A

What % of total variation is in the measuring system < 30%

62
Q

Takt Time

A

net time/demand (min per part)

63
Q

Tackt Rate

A

demand/units (parts per min)

64
Q

Wttk

A

E[setuptimei)+(Processingtimei x Batchsizei)]

65
Q

Non Normal data:

A

Idenifty: probiblity plot P>.05=Normal Use median, use non parametric, transform

66
Q

What is Parametic and non Parametric?

A

Parametric assumes normal ; nonparametric does not ;

67
Q

Name two normal Transformations:

A

Box Cox , Johnson

68
Q

Why 1st stratify?,

A

elimate ouliers, non normal may not matter, use non-parametircs

69
Q

Key parts of Improve

A

VSM, NVA analysis, tact charts, spaghetti charts, pareto charts, CE diagam, Control charts, Benift effort matrix
Solutions: brainstorm, 20Question, candid comments, random word, benchmark
Then: reduce, weight, rank, prioritize, CDAM, pariwise, force field, synthesize

70
Q

3 main cause of Failures

A

lubrication ( too much, too little, wrong kind) ; contaminants; loose parts

71
Q

example of Binary regression

A

Yes/no Pass/fail

72
Q

Example of ordinal regression

A

natural ordering, good better best, none, mild sever, fine ,medim, corse

73
Q

example of nominal regression

A

no natural order, blue red gree/, grass, trees, water

74
Q

PLT

A

sum of setup time + Sum Processing time + Sum Queue time+ sum of transport time + Sum of other delays;Average PlTs for each part then Plt=wip/exits

75
Q

PLT

A

WIP/Exit Rate (Little?s Law)

76
Q

PLT must include

A

Last item thru

77
Q

PLT is not equal to

A

thruput or exit rate

78
Q

WIP

A

PLT(ER)

79
Q

ER

A

WIP/PLT

80
Q

ER

A

Exits over Time

81
Q

PCE

A

VA/PLT

82
Q

VA

A

PCE(VA)

83
Q

RTY

A

(Rolled Thruput Yeild)Probability of Product passing thru entire process without defects

84
Q

RTY

A

Product of each step

85
Q

Tackt Time

A

Worktime/Units (Min per part) (Time per piece)

86
Q

Tack Rate

A

Demand/Units (Parts per min) (Pieces per time)

87
Q

Capacity

A

Max output over time

88
Q

CP

A

> 1.33 or 1.67 for critical

89
Q

CP

A

USL-LSL/6*sigma

90
Q

CP

A

<variation less than spec limits

91
Q

CPK

A

MIN[USL-XBar/3*Sigma or Xbar ?LSL/3Sigma] Use smaller

92
Q

Six Sigma

A

3 defects in a million

93
Q

RISK RPM

A

Severity X Occurance X Detection

94
Q

Bartlet

A

Normal

95
Q

Levene

A

Non Normal

96
Q

Anova not good for

A

non normal with outliers. Use Mood?s Median

97
Q

RACI

A

Responsiblie, Accountable, Consulted, Informed

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