IMPROVE PHASE Flashcards
DOE
DESIGN OF EXPERIMENTS
LEAN TOOLS MOST COMMON
BRAINSTORMING, BENCHMARKING, LEAN SOLUTIONS(5S, KANBAN, PULL SYSTEM, SOP, VISUAL MANAGEMENT), MISTAKE-PROOFING, REGRESSION ANALYSIS, DOE, KANBAN
WHAT IS THE IMPROVEMENT HIERARCHY?
AWARENESS, TRAINING(CERTIFICATIONS/AUDTIS), SIMPLIFICATION( ELIMINATE ACTIVITY) , FAIL-PROOF, FULL AUTOMATION
TRIZ PRINCIPLE A PROBLEM DEFINED BY
A. FACTS
B. CONTRADICTIONS
A PROBLEM IS DEFINED BY CONTRADICTIONS IMPROVING ONE PARAMETER IMPACTS NEGATIVELY ON ANOTHER.
HOW MANY KINDS OF CONTRADICTIONS
PHYSICAL AND TECHNICAL
T/F 39/39 used for general solutions
FALSE used for technical contradictions
T/F 40 Principles used for possible general solutions
True most feasible solution selected after evaluating all solutions
What TRIZ principle is used to solve the physical contradiction with 40 principles? In space, in time, between whole project/parts, through changing conditions
SEPARATION
EX) traffic lights, bicycle chain being flexible
WHAT THE 5S
SORT, SET IN ORDER, SHINE,STANDARDIZE, SUSTAIN
RED TAG RULE OF THUMB ONCE/TWICE A YEAR\_\_\_\_\_ ONCE/TWICE A MONTH\_\_\_\_\_ ONCE A WEEK\_\_\_\_ ONCE A DAY\_\_\_\_\_\_
STORE IN A DISTANT PLACE
STORE IN THE FACILITY
STORE IN NEARBY AREA
KEEP AT WORKPLACE
EXAMPLES OF SET IN ORDER
MAKE THINGS EASY TO USE/FIND OUTLINES, LABELS, COLOR CODING
EXAMPLES OF STANDARDIZATION
HOLDING AREAS, PROCEDURES, LOCATION
EXAMPLES OF SUSTAIN (MANAGE)
TRAINING, MONITORING, AUDIT, COMMUNICATE
WHAT IS VISUAL FACTORY? “CLARITY & TRANSPARENCY”
GRAPHICAL METHOD TO DISPLAY/COMMUNICATE HOW A PROCESS IS MANAGED, CONTROLLED IN REAL TIME
WHAT TYPE OF MANAGEMENT: 5S, ANDON LIGHTS, KANBAN, VISUAL STANDARDS, PROCESS INDICATORS, INFORMATION BOARDS
VISUAL FACTORY MANAGEMENT
T/F Kanban is a quick fix for large inventory problems, workforce issues, poor product planning, fluctating demand cycles
False
is used based on usage rate & lead time/replenishment interval
Kanban Size
= replenishment interval QTY + buffer QTY/ # of kanbans (items per bin/container)
used to detect problems automatically at an early stage
Jidoka & Andon
used to highlight a detect before its passed to the next operation
Poka Yoke
Used to ensure the effectiveness of machine/equipment in a system
TPM Total Productive Maintenance
Performance X Availability X Quality=
OEE Overall equipment effectiveness
speed at which the process runs a % of its designed speed
performance
% of the schedules time that the system is available to operate
Availability
known as first pass yield FPY- good units produced as a % of the total units produced
Quality
Single minute exchange die activities used in manufacturing industry to reduce changeover time
SMED- achieved in less than 10 minutes
used to predict mistakes, detect, & control method
Mistake proofing ( visual inspection eliminated, process simplified, immediate action is taken)
List human errors
forgetfulness, language barriers, misunderstandings, lack of experience, pace, lack of standards, expectations, procedures, incorrect/incomplete processing
mistake proofing methods must be documents in
a. FMEA
b. SIPOC
c. CONTROL PLAN
FMEA & CONTROL PLAN
Types of solutions (3)
Must Criteria, Cost-Benefit Analysis, Prioritization Matrix
examples of this criteria for soultion: legal regulations safety regulations fulfilling customer requirements company strategy/philosophy internal company agreements norms and standards ecological requirements
MUST CRITERIA
Evaluate cost-benefit
12 months _____ to project start
12 months _____ implementing improvements
prior : after
used for determining the most important solution
Prioritization Matrix
Ways to determining the risks in implementing the best solution
Mistake-proofing, 5 WHYS, FMEA (failure mode & effects analysis)
Steps for risk analysis
- evaluate impact risks
- formulate potential risks
- determine a reaction plan
- formulate potential risks
- evaluate impact risks
- determine a reaction plan such as mitigation, contingency, transfer
how to implement the best solution
future state map, VSM—> update SOP —-> Pilot run
assumes a linear relationship between a single X & Y
simple Linear
Multiple Linear
assumes a linear relationship between several Xs & Ys
Simple Linear Regression SLR determines the relationship between _____ and 1 continuous input/predictor/factor (X)
a continuous output
primary reasons for fitting a linear regression equation to the observed data?
- Describe data
- To predict the ____ value of an output variable for a specified value of input variable
EXPECTED
also known as the coefficient of determination
R-Squared
What is the residual (e)
distance from the line to the data point
both the sum and mean of the residuals are equal to___
0, if not equal to 0 then data is biased
t/f regression model considered inappropriate if 3 assumptions are NOT true
TRUE
What are the 3 assumptions about the residual:
residual distributed normal
Equal variance w/ respect to fitted value
Unrelated residual w/ each other
if not true for simple linear regression, then consider polynomial regression model or use transformation technique
in minitab for simple liner regression
stat>regression>fitted line plot>graph> standardized
3 main points about residual pets
- residuals are ______ distributed
- residuals have a ____ variance
- residuals are ______ with each other
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
What is MRA
multiple regression analysis
if the p value is less than 0.05 then we
reject the null & conclude that a significant difference exists
