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6 sigma methodologies > IMPROVE PHASE > Flashcards

IMPROVE PHASE Flashcards

1
Q

DOE

A

DESIGN OF EXPERIMENTS

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2
Q

LEAN TOOLS MOST COMMON

A

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

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3
Q

WHAT IS THE IMPROVEMENT HIERARCHY?

A

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

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4
Q

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

A

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

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5
Q

HOW MANY KINDS OF CONTRADICTIONS

A

PHYSICAL AND TECHNICAL

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6
Q

T/F 39/39 used for general solutions

A

FALSE used for technical contradictions

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7
Q

T/F 40 Principles used for possible general solutions

A

True most feasible solution selected after evaluating all solutions

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8
Q

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

A

SEPARATION

EX) traffic lights, bicycle chain being flexible

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9
Q

WHAT THE 5S

A

SORT, SET IN ORDER, SHINE,STANDARDIZE, SUSTAIN

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10
Q 
RED TAG RULE OF THUMB
ONCE/TWICE A YEAR\_\_\_\_\_
ONCE/TWICE A MONTH\_\_\_\_\_
ONCE A WEEK\_\_\_\_
ONCE A DAY\_\_\_\_\_\_
A

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

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11
Q

EXAMPLES OF SET IN ORDER

A

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

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12
Q

EXAMPLES OF STANDARDIZATION

A

HOLDING AREAS, PROCEDURES, LOCATION

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13
Q

EXAMPLES OF SUSTAIN (MANAGE)

A

TRAINING, MONITORING, AUDIT, COMMUNICATE

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14
Q

WHAT IS VISUAL FACTORY? “CLARITY & TRANSPARENCY”

A

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

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15
Q

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

A

VISUAL FACTORY MANAGEMENT

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16
Q

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

A

False

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17
Q

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

A

Kanban Size

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

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18
Q

used to detect problems automatically at an early stage

A

Jidoka & Andon

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19
Q

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

A

Poka Yoke

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20
Q

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

A

TPM Total Productive Maintenance

21
Q

Performance X Availability X Quality=

A

OEE Overall equipment effectiveness

22
Q

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

A

performance

23
Q

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

A

Availability

24
Q

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

A

Quality

25
Q

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

A

SMED- achieved in less than 10 minutes

26
Q

used to predict mistakes, detect, & control method

A

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

27
Q

List human errors

A

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

28
Q

mistake proofing methods must be documents in

a. FMEA
b. SIPOC
c. CONTROL PLAN

A

FMEA & CONTROL PLAN

29
Q

Types of solutions (3)

A

Must Criteria, Cost-Benefit Analysis, Prioritization Matrix

30
Q 
examples of this criteria for soultion:
legal regulations
safety regulations
fulfilling customer requirements
company strategy/philosophy
internal company agreements
norms and standards
ecological requirements
A

MUST CRITERIA

31
Q

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

A

prior : after

32
Q

used for determining the most important solution

A

Prioritization Matrix

33
Q

Ways to determining the risks in implementing the best solution

A

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

34
Q

Steps for risk analysis

  1. evaluate impact risks
  2. formulate potential risks
  3. determine a reaction plan
A
  1. formulate potential risks
  2. evaluate impact risks
  3. determine a reaction plan such as mitigation, contingency, transfer
35
Q

how to implement the best solution

A

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

36
Q

assumes a linear relationship between a single X & Y

A

simple Linear

37
Q

Multiple Linear

A

assumes a linear relationship between several Xs & Ys

38
Q

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

A

a continuous output

39
Q

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
A

EXPECTED

40
Q

also known as the coefficient of determination

A

R-Squared

41
Q

What is the residual (e)

A

distance from the line to the data point

42
Q

both the sum and mean of the residuals are equal to___

A

0, if not equal to 0 then data is biased

43
Q

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

A

TRUE

44
Q

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

A

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

45
Q

in minitab for simple liner regression

A

stat>regression>fitted line plot>graph> standardized

46
Q

3 main points about residual pets

  1. residuals are ______ distributed
  2. residuals have a ____ variance
  3. residuals are ______ with each other
A

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

47
Q

What is MRA

A

multiple regression analysis

48
Q

if the p value is less than 0.05 then we

A

reject the null & conclude that a significant difference exists

6 sigma methodologies (13 decks)

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