C1 M3- Lean and Six Sigma methodologies

Question 1

What is the main principle of Lean methodology?

Answer 1

The removal of waste within an operation by optimizing process steps and adding value at each phase of production.

Question 2

What are the eight types of waste identified in Lean Manufacturing?

Answer 2

1. Defects
2. Excess processing
3. Overproduction
4. Waiting
5. Inventory
6. Transportation
7. Motion
8. Non-utlised talent

Question 3

What issues commonly create waste in Lean project management?

Answer 3

• Lack of proper documentation
• Lack of process standards
• Not understanding customers’ needs
• Lack of communication
• Lack of process control
• Inefficient process design
• Failures of management

Question 4

When should you implement Lean project management?

Answer 4

When you want to use limited resources, reduce waste, and streamline processes for maximum benefits.

Question 5

What is the Lean 5S quality tool, and what does it aim to achieve?

Answer 5

The 5S tool stands for sort, set in order, shine, standardize, and sustain. It aims to clean and organize the workplace to reduce wasted time and material.

Question 6

What are the five steps of the 5S method?

Answer 6

1. Sort: Remove unnecessary items.
2. Set in order: Arrange and label needed items.
3. Shine: Clean and maintain the workspace daily.
4. Standardize:Perform processes the same way every time.
5. Sustain: Maintain procedures as a habit and instill discipline in the team.

Question 7

What is a Kanban board, and how is it used in Lean methodology?

Answer 7

A Kanban board is a visualization tool that optimizes workflow by showing progress through cards moved from left to right in columns such as “To Do,” “In Progress,” “Testing,” and “Done.”

Question 8

What is the main goal of Six Sigma methodology?

Answer 8

To reduce variations and ensure quality processes are followed every time, achieving 99.9996% quality.

Question 9

What are the seven key principles of Six Sigma?

Answer 9

1. Always focus on the customer.
2. Understand how work gets done.
3. Make processes flow smoothly.
4. Reduce waste and concentrate on value.
5. Stop defects by removing variation.
6. Involve and collaborate with your team.
7. Approach improvement systematically.

Question 10

How does Six Sigma handle unacceptable products?

Answer 10

It inspects measurable items like time, cost, or quantity and rejects products that don’t meet standards. The processes creating unacceptable products must be improved.

Question 11

What is Lean Six Sigma, and how does it combine both methodologies?

Answer 11

Lean Six Sigma combines Lean’s process streamlining tools (like 5S and Kanban) with Six Sigma’s focus on reducing variation and meeting high-quality standards, increasing project efficiency.

Question 12

What is the largest difference between Lean and Six Sigma methodologies?

Answer 12

Lean streamlines processes, while Six Sigma reduces variation in products by building quality from the beginning and inspecting for quality standards.