Final Exam Review Flashcards
Make-to-Order-Hierarchy
Lean is:
- Driving Value (Defined by customer, VOC)
- Make waste visible
- Elimination of waste
- Goal is: Make-to-Order-PULL (MTO-Pull)
Six-Sigma is:
- Driving Value (defined by customer, VOC)
- Variation Reduction
- Defect Elimination
- GOAL is: Cost Improvement Initiative
Value Stream Mapping
- Defines value and waste
- Map of the current state of the flow of information and materials in a process
-
Value
- Value-added activitiies (Improve)
- What the customer is happy/willingto pay for
- Non-Value added activities (Eliminate)
- Business-Value added activities (Reduce)
- Value-added activitiies (Improve)
-
Waste
- Refer to 8 Wastes
- Underutilized Talent, Motion, Waiting, Transportation, Over-Production, Over-Processing, Inventory, Defects.
-
Flow
- Rapid sequence, sufficient capacity, shortest cycle time.
-
Pull
- Work is initiated by kanban, work is limited to value added activities, synchronization, minimal inventory.
Value-Added Activities
Time during which value is added in the eyes of the customer.
Cycle Time
Time between two products produced by a
certain process step
- Throughput Time
- Machine tact time
Throughput
Number of products produced per unit time.
- Throughput rate
- Machine speed-production rate
Total Cycle Time
Time product flows from first process until
last process step for given routing
- Process/total throughput time
- Consists of Cycle Time and Changover Time.
SIPOC
- Suppliers
- Inputs
- Processes
- Outputs
- Customers
A high-level map used to find areas of improvement.
8 Wastes
- Under-Utilized Talent
- Motion
- Waiting
- Transportation
- Over-Production
- Inventory
- Defects
- Over-Processing
DMAIC
D - Define
M - Measure
A - Analyze
I - Improve
C - Control
What is a good approach to sampling?
Random and stratified
What is the RTY (Rolled Thoroughput Yield) of 90%, 80%, 70%?
It is the product of all percentages multiplied out:
.9*.8*.7 = 50%
What tool is best used to identify all potential critical x’s?
A Process Map
Which flowchart technique highlights processes w/ people?
Activity Flow Map
The Kano model shows?
Relationships between “must haves” and delighters
An Affinity diagram allows you to?
Categorize and group like things together.
When sampling, precision is a measure of?
How much of a difference makes a difference
Y in the statement Y=f(x1,x2,x3…) means?
Process output
Design of Experiments (DOE) is used to?
DOE is used to prove causation.
What is mistake proofing and why do it?
Known as Poka-yoke, it is used for the elimination of error.
What should you use to select a solution?
Solution Priortization Matrix
Name 2 reasons to pilot a solution:
- Prove or validate the expected results
- Better understand the risks
- Facilitates the buy-in for smoother implementation.
Name the 3 rating elements used in FEMA. Which one usually doesn’t change when you reduce overall risk?
Severity, Occurrence, Detection. Severity usually never changes, it’s typically the same impact as before the change took place.
Project Charter contains:
Scope, Objective, Business Case
What is Change Management?
Getting individuals and groups READY, WILLING, and ABLE to implement new processes.
What is the main focus of a change-management plan?
People Factor
What is RTY of a three step process, all having 95%?
.95*3/3 = 95%
What are the types of variation?
Common and Special causes
Common - historical or expected cause
Special - an outlier or unexpected event
Name 3 reasons why batch processing should be avoided?
- Creates WIP
- Increases opportunity for damage
- Increases inventory carry costs
- It is a ridged process that accomodates the batch size only.
Name 2 reasons a ‘good’ change fails?
- Poor communication
- Lack of tangible results
- Everything is a high priority
- VOC is not heard
What are the 3 critical factors in preparing an organization for change?
- Planning
- Communication
- Organization
- Buy-In
What does PDCA stand for? Why do it?
Plan, Do, Check, Act. Use it when developing or implementing a new process.
PDCA Cycle for Standardization
What flowchart best highlight handoffs between processes and functions?
Activity Flowchart or Swim Lane flowchart.
Go here, then here, then to sales, etc….
Describe a process that is performing at Six Sigma:
3.4 defects per million opportunity
The closest specification limit is no closer than six standard deviations away.
What is the name of the document that describes in detail how to execute a process or step? Who MUST be involved in it’s creation?
SOP - Standard Operating Procedures
The one responsible for executing the process (machine operator) MUST be included in it’s creation.
To assure that a process will achieve an expected result, it is important to monitor what?
The critical x’s (in-process variables) that were proven to be cause and effect.
What visual process/tool determines if a process is in control or not?
Control Chart
Name 3 costs of failed change?
- Wasted resources
- Business objectives are not met
- Moral suffers
- Long-term strategies are not achieved
What does the 5’s stand for?
- Sort
- Shine
- Standardize
- Sustain
- Stabilize
What can be achieved by applying the tools, methods, and the start of six-sigma?
In the quest for Make-To-Order you reduce the Supply Chain cost by removing waste and variation, inherently improving quality, and customer satisfaction.
What is a FMEA?
Failure, Mode, Effect, Analysis.
- Structured approach to identify, estimate, prioritize and evaluate risk.
- Aims at failure prevention
- Primarily used to limit the risk involved in changing the process.
