Improve

Question 1

What question does the IMPROVE phase answer?

Answer 1

How do we solve the problem?

Question 2

How does one generate solutions to determined root causes?

Answer 2

Obvious solutions
Optimization of input & process parameters
Best practices
Lean Approaches
Creative techniques

Question 3

What are the primary LEAN approaches to generating solutions in the Improve phase? Briefly describe each.

Answer 3

5S
Polka Yoke
Theory of Constraint (SMED)
Batch Size Reduction
Push-Pull Systems - Generic Pull System & Replenishment Pull System
Complexity

Question 4

What are the parts/steps of the Improve phase?

Answer 4

1. Generate solutions
2. Filter solutions
3. Finalize solutions
4. Implement solutions
5. Gate Review

Question 5

What are the primary Creativity Techniques to generate solutions in the Improve phase? Briefly describe each.

Answer 5

Brainstorm
Anti-solution Brainstorm
Walt Disney Method
World Cafe
Brain Writing

Question 6

Describe 5s.

Answer 6

A methodology to create & maintain an organized, clean, & highly efficient workspace.

1. Sort
2. Set in Order
3. Shine
4. Standardize
5. Sustain

Question 7

Describe Polka Yoke.

Answer 7

This is failure prevention. Focus on prevention approach before reactive approach.
Why? Mistakes cost $$$, and cost increases as the process moves along.

Question 8

Describe the Theory of Contraint

Answer 8

1. Identify constraint - Takt time or Takt rate; tells you about customer demand
2. Optimize constraint - Reduce processing time, shift employee count, increase # shifts
   **Special Tool: SMED
3. Subordinate everything else - Make sure the constraint has the priority
4. Elevate the constraint - Buy new equipment
5. Repeat

Question 9

What is SMED?

Answer 9

Single Minute Exchange of Dies

A special tool used to optimize the constraint in a process.

1. Document process (video tape)
2. Determine Internal & External parts of process
   
   • Internal: machine stopped
   • External: machine running
3. Optimize internal activities
4. Optimize adjustments

Goal: Transfer internal to external, e.g. do prep work while machine is working on previous output

Question 10

Describe the 3 types of Push-Pull Systems.

Answer 10

Push - output & information moving the same direction; not ideal; forecast based planning
Generic Pull system - introduce signal from output side, sending to input side; orient process towards meeting actual demand
Replenishment Pull system - demand oriented control; signal to avoid high capital utilization (keep WIP low) or over production

Question 11

What is Kanban?

Answer 11

A signal that a refill is needed. Either paper or digital.

Question 12

Describe the 5 main creativity techniques for solving the problem.

Answer 12

Brainstorm - open (facilitator) or closed (written)
Anti-solution brainstorm - ask question in negative way; collect ideas to make it worse
Brian writing (6-3-5 method): 6 people, 3 ideas written, 5 minutes
Walt Disney method: dreamer, critic, realist role play
World Cafe - topic at each table, write down ideas 15 minutes, rotate; for large groups

Question 13

How would someone filter possible solutions?

Answer 13

Solution criteria: improve CTC, regulations/laws, EHS
Use an effort-benefit matrix.

Question 14

How would someone finalize solutions in the Improve phase?

Answer 14

Process documentation
SOPs - photos
Roles & responsibilities (RACI)

Question 15

How would someone Implement solutions in the Improve phase?

Answer 15

Determine implementation plan (objectives, RACI, actions, timeline, budget, change management)
Pilot (Deming Cycle/PDCA - Plan.Do.Check.Act) - show benefits, get buy-in, create acceptance, minimize risks, avoid failing

Question 16

Describe how to setup and use an effort-benefit matrix.

Answer 16

Effort vs. Benefit
Low, med, high for each
Break into 3 sections.
High effort, low benefit - throw away
Low effort, high benefit - implement
Middle - clarify with sponsor
Low effort, low benefit - quick wins