IMPROVE PHASE

Question 1

DOE

Answer 1

DESIGN OF EXPERIMENTS

Question 2

LEAN TOOLS MOST COMMON

Answer 2

BRAINSTORMING, BENCHMARKING, LEAN SOLUTIONS(5S, KANBAN, PULL SYSTEM, SOP, VISUAL MANAGEMENT), MISTAKE-PROOFING, REGRESSION ANALYSIS, DOE, KANBAN

Question 3

WHAT IS THE IMPROVEMENT HIERARCHY?

Answer 3

AWARENESS, TRAINING(CERTIFICATIONS/AUDTIS), SIMPLIFICATION( ELIMINATE ACTIVITY) , FAIL-PROOF, FULL AUTOMATION

Question 4

TRIZ PRINCIPLE A PROBLEM DEFINED BY
A. FACTS
B. CONTRADICTIONS

Answer 4

A PROBLEM IS DEFINED BY CONTRADICTIONS IMPROVING ONE PARAMETER IMPACTS NEGATIVELY ON ANOTHER.

Question 5

HOW MANY KINDS OF CONTRADICTIONS

Answer 5

PHYSICAL AND TECHNICAL

Question 6

T/F 39/39 used for general solutions

Answer 6

FALSE used for technical contradictions

Question 7

T/F 40 Principles used for possible general solutions

Answer 7

True most feasible solution selected after evaluating all solutions

Question 8

What TRIZ principle is used to solve the physical contradiction with 40 principles? In space, in time, between whole project/parts, through changing conditions

Answer 8

SEPARATION

EX) traffic lights, bicycle chain being flexible

Question 9

WHAT THE 5S

Answer 9

SORT, SET IN ORDER, SHINE,STANDARDIZE, SUSTAIN

Question 10

RED TAG RULE OF THUMB
ONCE/TWICE A YEAR\_\_\_\_\_
ONCE/TWICE A MONTH\_\_\_\_\_
ONCE A WEEK\_\_\_\_
ONCE A DAY\_\_\_\_\_\_

Answer 10

STORE IN A DISTANT PLACE
STORE IN THE FACILITY
STORE IN NEARBY AREA
KEEP AT WORKPLACE

Question 11

EXAMPLES OF SET IN ORDER

Answer 11

MAKE THINGS EASY TO USE/FIND OUTLINES, LABELS, COLOR CODING

Question 12

EXAMPLES OF STANDARDIZATION

Answer 12

HOLDING AREAS, PROCEDURES, LOCATION

Question 13

EXAMPLES OF SUSTAIN (MANAGE)

Answer 13

TRAINING, MONITORING, AUDIT, COMMUNICATE

Question 14

WHAT IS VISUAL FACTORY? “CLARITY & TRANSPARENCY”

Answer 14

GRAPHICAL METHOD TO DISPLAY/COMMUNICATE HOW A PROCESS IS MANAGED, CONTROLLED IN REAL TIME

Question 15

WHAT TYPE OF MANAGEMENT: 5S, ANDON LIGHTS, KANBAN, VISUAL STANDARDS, PROCESS INDICATORS, INFORMATION BOARDS

Answer 15

VISUAL FACTORY MANAGEMENT

Question 16

T/F Kanban is a quick fix for large inventory problems, workforce issues, poor product planning, fluctating demand cycles

Answer 16

False

Question 17

is used based on usage rate & lead time/replenishment interval

Answer 17

Kanban Size

= replenishment interval QTY + buffer QTY/ # of kanbans (items per bin/container)

Question 18

used to detect problems automatically at an early stage

Answer 18

Jidoka & Andon

Question 19

used to highlight a detect before its passed to the next operation

Answer 19

Poka Yoke

Question 20

Used to ensure the effectiveness of machine/equipment in a system

Answer 20

TPM Total Productive Maintenance

Question 21

Performance X Availability X Quality=

Answer 21

OEE Overall equipment effectiveness

Question 22

speed at which the process runs a % of its designed speed

Answer 22

performance

Question 23

% of the schedules time that the system is available to operate

Answer 23

Availability

Question 24

known as first pass yield FPY- good units produced as a % of the total units produced

Answer 24

Quality

Question 25

Single minute exchange die activities used in manufacturing industry to reduce changeover time

Answer 25

SMED- achieved in less than 10 minutes

Question 26

used to predict mistakes, detect, & control method

Answer 26

Mistake proofing ( visual inspection eliminated, process simplified, immediate action is taken)

Question 27

List human errors

Answer 27

forgetfulness, language barriers, misunderstandings, lack of experience, pace, lack of standards, expectations, procedures, incorrect/incomplete processing

Question 28

mistake proofing methods must be documents in a. FMEA b. SIPOC c. CONTROL PLAN

Answer 28

FMEA & CONTROL PLAN

Question 29

Types of solutions (3)

Answer 29

Must Criteria, Cost-Benefit Analysis, Prioritization Matrix

Question 30

``` examples of this criteria for soultion: legal regulations safety regulations fulfilling customer requirements company strategy/philosophy internal company agreements norms and standards ecological requirements ```

Answer 30

MUST CRITERIA

Question 31

Evaluate cost-benefit 12 months _____ to project start 12 months _____ implementing improvements

Answer 31

prior : after

Question 32

used for determining the most important solution

Answer 32

Prioritization Matrix

Question 33

Ways to determining the risks in implementing the best solution

Answer 33

Mistake-proofing, 5 WHYS, FMEA (failure mode & effects analysis)

Question 34

Steps for risk analysis 1. evaluate impact risks 2. formulate potential risks 3. determine a reaction plan

Answer 34

1. formulate potential risks 2. evaluate impact risks 3. determine a reaction plan such as mitigation, contingency, transfer

Question 35

how to implement the best solution

Answer 35

future state map, VSM---> update SOP ----> Pilot run

Question 36

assumes a linear relationship between a single X & Y

Answer 36

simple Linear

Question 37

Multiple Linear

Answer 37

assumes a linear relationship between several Xs & Ys

Question 38

Simple Linear Regression SLR determines the relationship between _____ and 1 continuous input/predictor/factor (X)

Answer 38

a continuous output

Question 39

primary reasons for fitting a linear regression equation to the observed data? 1. Describe data 2. To predict the ____ value of an output variable for a specified value of input variable

Answer 39

EXPECTED

Question 40

also known as the coefficient of determination

Answer 40

R-Squared

Question 41

What is the residual (e)

Answer 41

distance from the line to the data point

Question 42

both the sum and mean of the residuals are equal to___

Answer 42

0, if not equal to 0 then data is biased

Question 43

t/f regression model considered inappropriate if 3 assumptions are NOT true

Answer 43

TRUE

Question 44

What are the 3 assumptions about the residual: residual distributed normal Equal variance w/ respect to fitted value Unrelated residual w/ each other

Answer 44

if not true for simple linear regression, then consider polynomial regression model or use transformation technique

Question 45

in minitab for simple liner regression

Answer 45

stat>regression>fitted line plot>graph> standardized

Question 46

3 main points about residual pets 1. residuals are ______ distributed 2. residuals have a ____ variance 3. residuals are ______ with each other

Answer 46

Normally- probability plot constant - using a fitted graph uncorrelated (biased) using observation order graph Histogram shows skewed or outliers Tools>options>Linear Models>Residual Plots

Question 47

What is MRA

Answer 47

multiple regression analysis

Question 48

if the p value is less than 0.05 then we

Answer 48

reject the null & conclude that a significant difference exists