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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
Value Stream Mapping
, validates relationship between x & y, validates problem statement. No root cause nor solution in Problem statement.Validate with VOC & VOB
26
PROJECT MANAGEMENT Tools are used to
to balance scope, cost, time, requirements & customer expectations.
27
Name parts of project managment
define Roles, Triangle, Risk, Stakeholders,Communcation plan, team launch
28
What are the BB/PM Roles:
coordination, resource planning, organizing, leading, relationships, information, decision.
29
Triangle:
Time, cost, results (scope)(quality)
30
Risk:
identify, prioritization grid, ^Impact >Probability , Risk Response: Avoidance, transference(Insurance, warranty, guarantees) , mitigation, acceptance.
31
Stakeholders analysis?
Use: SH analysis matrix 1-5 resistance, passive R, Passive support Active S, strong S. Likelihood of support Matrix: 1-5
32
Communication Plan:
Audience & media Use: Action logs, Quad charts, status plan, RACI Chart
33
Teamlaunch:
Team, balance size,/skills,/social style,/mission, ground rules, RACI
34
Team Launch Deliverables
objective, goals, rules roles, responsibilities, draft project plan, roles and responsibilities, prework email, bring docs, 1-2 weeks ahead, mission, agenda, data commitment.
35
How do you organize ideas in team launch?
Affinitize ideas. Feadback: conflict, decisions, effectiveness. voting
36
Wrap up of project launch
: action items Summary: time, cost , quality, ongoing planning, sense ofurgncy, priorities, deliverables itemized, approval & sign off. PM/BB : plan, organize, implement, control
37
Discuss Variation & Common Cause
85-95% Wear, tem flux, material harness, experience, server response.
38
What is Tampering?
: over adjusting in response to noise=
39
What is Special cause?
other than common cause . Tools: run charts, control charts. 5-15% Special cause.
40
What is included in Define Gate?
: 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
Measure
charter, team, PM, tollgate checklist to sponsor
42
Types of Variability
: Accurcy, precison
43
Accuracy:
average measure = true vale
44
Bias :
difference between average and true
45
Sources of Bias?
Sources are operator, instrument, other (site, temp, customer, supplier)
46
What does Precision measure?:
Same results on same part
47
What does Repeatability measure?
inherent variation same part, person instrument. Also called gage precsiosn.
48
Reproduceablity
: variation by different operators using same tool
49
What is the difference betweenPrecision & accuracy
precision is the repeatblity samepart same tool. Accurace is the true value or average measure
50
What is Discrimination?
The ability of the tool to measure within your specifications
51
What does the Measure phase include?
: 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
Desccribe MSA
Variablity: Bias or instrument accuracy problems: clustered off center/Repeatability or Gage precisions issue:
53
What is the most important deliverable of measure?
Value Stream Mapping :Top is info, middle is process, bottom is time
54
8 forms of WASTE:
Time, inventory, motion, waiting, overproduction, overprocessing, defects/rework & People.
55
Describe types of Data
Continous/ Discrete
56
Name Data tools
Data measurement plan: Pareto, histogram, control chart, scatter diagram.
57
What is Stratfication?
What, when, where, who? ( complaints, dates, city, dept) Not too many or too little. Use: check sheets, frequency plots Consider: time, cost accuracy.
58
What is Inferential statistics?
Conclusions about population from sample.
59
Talk about Samples:
Random, prevent bias, stratified random, between and within. Minimize within so you can see between sample variation.
60
MSA: What are we measuring?
X= key process baseline. Y = Goal measure control. MSA for continuous data: Accuracy & Precision are most important in chart above.
61
What is %RR?
What % of total variation is in the measuring system < 30%
62
Takt Time
net time/demand (min per part)
63
Tackt Rate
demand/units (parts per min)
64
Wttk
E[setuptimei)+(Processingtimei x Batchsizei)]
65
Non Normal data:
Idenifty: probiblity plot P>.05=Normal Use median, use non parametric, transform
66
What is Parametic and non Parametric?
Parametric assumes normal ; nonparametric does not ;
67
Name two normal Transformations:
Box Cox , Johnson
68
Why 1st stratify?,
elimate ouliers, non normal may not matter, use non-parametircs
69
Key parts of Improve
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
3 main cause of Failures
lubrication ( too much, too little, wrong kind) ; contaminants; loose parts
71
example of Binary regression
Yes/no Pass/fail
72
Example of ordinal regression
natural ordering, good better best, none, mild sever, fine ,medim, corse
73
example of nominal regression
no natural order, blue red gree/, grass, trees, water
74
PLT
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
PLT
WIP/Exit Rate (Little?s Law)
76
PLT must include
Last item thru
77
PLT is not equal to
thruput or exit rate
78
WIP
PLT(ER)
79
ER
WIP/PLT
80
ER
Exits over Time
81
PCE
VA/PLT
82
VA
PCE(VA)
83
RTY
(Rolled Thruput Yeild)Probability of Product passing thru entire process without defects
84
RTY
Product of each step
85
Tackt Time
Worktime/Units (Min per part) (Time per piece)
86
Tack Rate
Demand/Units (Parts per min) (Pieces per time)
87
Capacity
Max output over time
88
CP
>1.33 or 1.67 for critical
89
CP
USL-LSL/6*sigma
90
CP
91
CPK
MIN[USL-XBar/3*Sigma or Xbar ?LSL/3Sigma] Use smaller
92
Six Sigma
3 defects in a million
93
RISK RPM
Severity X Occurance X Detection
94
Bartlet
Normal
95
Levene
Non Normal
96
Anova not good for
non normal with outliers. Use Mood?s Median
97
RACI
Responsiblie, Accountable, Consulted, Informed

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