Final Flashcards
Pass this fucking classs and never see Doug again
What is DPMO and what is the equation?
Defects per million opportunities
Number of Defects x 1,000,000) / (Number of Defect Opportunities per Unit x Number of Units
What is RACI?
Responsible – the doer
Accountable -only one person can be held accountable, many times it is the process owner, the person who can veto or approve process
Consulted – the individuals to be consulted prior to reaching a final decision or taking a final action
Informed – the individuals who need to be informed of a decision or action
What is change management?
- Pick the right team.
- Communicate the objective.
- Create a sense of urgency with personal relevance.
- Develop the strategy and action plan to meet the objective.
- Facilitate the natural team development process (Forming-Storming-Norming-Performing) -.
- Generate and celebrate short-term wins - build team spirit and confidence.
- Understand the balancing forces.
What is the fishbone diagram used for?
to find the root cause(s) of variation
What the different categories for the fishbone?
machine, method, man, mother nature, material
What is multiple regression used for?
used to see the correlation of multiple independent factors on the dependent variable
What are measures of dispersion?
how spread out a data set is
What is variance?
the avg squared distance between the mean and the individual observations
What does evaluating the pilot mean
What are you trying to improve and what do you have to prove that your process has improved
What are the different levels of the kano model?
- Basic - Dissatisfiers - Presence of these features or functions does not produce satisfaction, but their absence creates strong dissatisfaction.
- Performance - Satisfiers - Increasing these features or functions leads to higher satisfaction.
- Excitement - Delighter - Presence of these unexpected features or functions leads to “delight” or customers being “pleasantly surprised”.
Who approves a six sigma project?
the process owner
Who closes a six sigma project?
The customer?
What is a pull system?
A pull system is a system that does not move until the next step is ready for it to move. Each step down the line requests for a piece.
What is little’s law?
Converting inventory into time
Throughput Volume per unit time) = (WIP/Cycle Time)
What are the 5Cs?
Clear - sort Configure - set in order Clean and check - same as shine and check conformity - standardize consensus .- sustain
Why is it important to measure>
Measurement lays the ground work for preventing erros
What is takt time?
total processing time / qunatity demanded by the customer
What happens during the project kickoff?
The process owner approves the process?
What are the roles within a Six Sigma project?
Process owner - owns the process
Sponser / champion - senior managers who initiate, support, and shepard a project within their area of responsibility
Implementation leader - person for internal marketing of the program, responsibile for tracking resources and developing the infrastructure for training
green belt - team leaders or individual contributors
black belt - complete 5-6 projects a year, expert
Master black belt - train others in Six sigma
What does the pareto chart do?
The Pareto Chart shows the relative frequency of defects in rank-order, and thus provides a prioritization tool so that process improvement activities can be organized to “get the most bang for the buck”, or “pick the low-hanging fruit”.
What are andon boards used for?
displaying current production information such as actual production vs target, generally on a daily or shift by shift basis
What are the 5Ss?
Sort - seperate the unneeded items from the needed items
Standardize - Creating policies for things to remain in the locations that they are, so that there is no grey area.
set in order- everything should have a defined location
shine - Picking up after every shitft and keeping the workstartion clean
sustain - management must back the policies put into place so that things stay as they are
What is FMEA?
Failure Mode Effect Analysis
used in the improve phase, scores are assigned for 3 seperate catrgories: severity, occurence, and detection
overall score is the risk priority number - take all 3 and multiply to get the rpn
What is a CTQC tree?
starts with a gen need, how will you meet this need - these are the drivers, what does that mean of each driver - ctqs
What is a type I error?
when the null is true but you still reject it
What is a type II error?
when the null is false and you don’t reject it
What does SMED stand for?
Single Minute Exchange of Die
What was SMED created for?
to reduce inventory and increase efficiency
What are some ways to create quick changeover?
staged equipment
operations conducted in parallel
standardization of tools
pre tightening of bolts
What are the benefits to SMED?
reduced lead times and responsiveness to customers
improved product quality
flexibility to respond to changes in demand
moves facility from push to pull system
What are control charts used for?
used to distinguish special from common cause variation
What are the out of control conditions?
o If one or more points falls outside of the upper control limit (UCL), or lower control limit (LCL). The UCL and LCL are three standard deviations on either side of the mean - see section A of the illustration below.
o If two out of three successive points fall in the area that is beyond two standard deviations from the mean, either above or below - see section B of the illustration below.
o If four out of five successive points fall in the area that is beyond one standard deviation from the mean, either above or below - see section C of the illustration below.
o If there is a run of six or more points that are all either successively higher or successively lower - see section D of the illustration below.
o If nine or more points fall on either side of the mean - see section E of the illustration below.
o If 15 points in a row fall within the area on either side of the mean that is one standard deviation from the mean - see section F of the illustration below.
if there are 14 points in a row alternating up and down - this shows that you have two processes
What is a p chart?
Used to chart the fraction defective when the subgroup size is variable or constant (although usually greater than 50). This chart assumes that the process has a binomial distribution
What is a c chart?
Used to chart the number of defects when the subgroup size is constant (although usually greater than 50). This chart assumes that the process has a Poisson distribution.
What is a np chart?
Used to chart the number of defective units when the subgroup size is constant (usually greater than 50). This chart assumes that the process has a binomial distribution
What is a u chart?
Used to chart the number of defects per unit when the subgroup size is variable or constant. This chart assumes that the process has a Poisson distribution.
What is the cause and effect matrix used for?
is used to prioritize the process inputs (causes, or X’s) that have been identified as potentially contributing to an Effect (Y).
What is stability?
refers to the capacity of a measurement system to produce the same values over time when measuring the same sample
What is stability in terms of SPC?
it means the absnece of special cause variation leaving only common cause variation
What is bias?
the measure of the distance between the avg value of the measurements and the actual value of the measurements
What is linearity?
a measure of the consistancy of bias over the range of the measurement device
What is repeatbility?
assesses whether the same appraiser can measure the same part/sample multiple times with the same measurement device and get the same value.
What is reproducibility?
assesses whether different appraisers can measure the same part/sample with the same measurement device and get the same value.
Why do we perform a Gage R+R?
to see if the measurement system is good - to see if it is reproducible
if percent agreement is high, then it is good
What is a main effect?
the effect a factor under investigation has on the response variable
What is interaction?
an effect of a factor on the response variable depends on the level of another factor
What is the equation for full factorial design?
(#levels)^#factors
FMEA: Describe the 3 different categories
severity - seriosuness of a failure
occurence - liklihood of a failure
detection - the liklihood that a failure will be detected prior to a release to a customer
What is the affinity diagram?
used in the define phase
Takes a group of people and has them brainstorm together by giving out different ideas. The ideas are grouped together in various groups that naturally form
Leads to ctqc
What does the process owner do?
takes responsibility of an entire process
What does the sponser / champion do?
ensures that the process goes across the goal line , all revisions should be approved by the champion
What does the implementation leader do?
leads the Six Sigma program for the company, identify champion / sponser candidates
What does a Green belt do?
may be team leaders or individual contributors depending on the structure embraced by the org
What does the black belt do?
complete 5-6 projects a year
What does a master black belt do?
train in Six Sigma
What is SIPOC map and what is it used for?
SIPOC – Supplier, inputs, process, output, control – used to identify all relevant elements of a process improvement project before work begins, helps define a complex project that may not be well scoped
What is a flow chart used for?
shows decision points, if/then logic
What is a swimlane chart used for?
identifies functional responsibilites, communicates who does what
What is the purpose of a SIPOC map?
to identify waste and prioritize Six Sigma projects, to understand relationships between inputs and outputs
What is a value added flow chart and what is the purpose of it?
seperates value adding from non value added activities, used to improve cycle times and productivity
What is a spaghetti diagram?
shows physical flow of information or materials, shows physical complexity, cycle times
What is a value stream map and what is its purpose?
identifies physical flow of materials and information, detailed improvement maps for lean improvement projects and kaizen events
What is a system diagram?
focused on cause and effect, examines behavior behind process performance
What are the three parts of the Kano model? Describe these
- Basic - Dissatisfiers - Presence of these features or functions does not produce satisfaction, but their absence creates strong dissatisfaction.
- Performance - Satisfiers - Increasing these features or functions leads to higher satisfaction.
- Excitement - Delighter - Presence of these unexpected features or functions leads to “delight” or customers being “pleasantly surprised”.
Describe kano paired questions
How do you feel if an attribute exists
How do you feel if an attribute doesn’t exist
What is nominal data?
attribute data
What is interval data?
count
What is ratio data?
continuous
What is ordinal data?
order matters
What is the resolution?
tolerance / 10 - the sensitivity of the gage, what are we measuring to?
Explain the deming funnel experiment
- Rule 1 of the Deming funnel experiment
- The funnel remains fixed, aimed at the target. In this case the target is located at the coordinates (0,0). X1 and Y1 are the coordinates of the point where the marble drops.
- Rule 2 of the Deming funnel experiment
- Move the funnel from its previous position a distance equal the current error (location of drop), in the opposite direction.
- Rule 3 of the Deming funnel experiment (Bow Tie Effect)
- Move the funnel to a position that is exactly opposite the point where the last marble dropped, relative to the target.
- Rule 4 of the Deming funnel experiment (Random Walk)
- Move the funnel to the position where the last marble dropped.
