Improve Phase Flashcards
What is the improve phase?
What are the solutions for eliminating the root causes
What are the 5 different solution approaches/stages?
Quick hits
Good practice
Simulation
Looking at current approaches
Refine creativity techniques
What are the 4 lean approaches in the improve phase?
Defects
Constraints
Inventory
Complexity
What is used as a lean approach for defects and make it error free?
Poka Yoke
What is used as a lean approach for constraints?
Reduction and theory of constraint
What is used as a lean approach for inventory?
Pull systems
What is used as a lean approach for complexity?
Process maps
What is the purpose of the 5 S’s
To create a clean, structured and highly efficient workplace
What are the 5 S’s?
Sort
Set in order
Shine
Standardized
Sustain
What does it mean to sort?
Remove what you do not need
What does it mean to set in order?
To bring in things to a useful order
What does it mean to shine?
Clean up and maintain
What does it mean to standardize?
Implement standard SOP’s
What does it mean to sustain?
Build up routines and responsibilities
What is Poka Yoke?
To make unintentional mistakes impossible and error proof
What are the two types of Poka Yoke?
Preventive
Reactive
What is SMED stand for?
Single minute exchange of die
What is the process for SMED?
Document the process
Transform internal into external activities
Optimize internal activities
Optimize adjusting
What is a push system?
A production line that pushes the product forward to demand
What is a pull system?
Production based off of the customer dictating the need
What is the theory of constraints? 5 things
Identify the constraint
Exploit the constraint
Align to the constraint
Elevate the constraint
Find the next constraint
Repeat
What are the two types of brainstorming?
Verbal and nonverbal, open or closed
What is brain writing?
Combination of open and closed brainstorming that is passed on a document among the team members and repeated
What is an anti-solution brainstorm?
How can we make things worse?
Who should be used in an anti-solution brainstorming session?
Critical members
What is an analogy brainstorm?
Relating the problem to people, colors, nature, competitors, etc.
What is the first step in the filter solutions process?
Sort out the impossible solutions
What are some examples of impossible solutions?
Legal or physical laws
Ethics or morality
Contracts
Business directives
Project Customer requirements
What is the second step of the filter solutions?
Sort out unfeasible solutions
How do you determine what is an unfeasible solution?
Define what effort and benefit is and how you scale it in a high medium low matrix
If applicable, how do you narrow down your solution pool even more after the effort benefit matrix?
N/3-number of votes for each team member
Normal grouping technique
N= number of ideas or solutions
Normal grouping technique -define the scale and discuss outliers
What does To-Be mean in finalizing solutions?
What do I need to add to make it ideal?
What 2 details are needed to complete a To-Be, finalized solution?
Define or clarify functions for the process
Build up the process according to the functions
What are the 6 categories of the To-Be process?
Functions – who does what?
Form – centralized system, process, layout
Definition – specify overall solution, and create process SOP (Lean, RACI, complexity)
Visualization – map the new process together with stakeholders from the process
Review – assess risk (risk, matrix, FMEA)
Communication – transfer results, get feedback and acceptance from stakeholders
What does FMEA stand for?
Failure mode effect analysis
What does FMEA do?
Looking for potential failures in the process steps
What is RPN?
Risk priority number
How do you calculate the RPN?
S x O x D
S= severity
O= occurrence
D = detection probability
How do you mathematically measure success?
Success = quality x acceptance
What is tool 4?
Cause solution matrix
What is the purpose for tool 4?
Do I have a solution for every root cause?
Are the solutions conflict free?
What does PDCA stand for?
Plan
Do
Check
Act
What is the first step in implementing solutions?
Coming up with a plan that contains:
Responsibilities
Time
Budget
Risk
Communication
What is the purpose of the KPI charter?
To actively steer the KPI’s in focus and react to deviations as early as possible
What is all included in your KPI charter? 7 things
KPI
Operational definition
Specification limit
Sampling
Responsibilities
Sponsor and process owner
Control charts
What are the 4 goals of the gate review for the improve phase?
Generate solutions
Refine and filter solutions
Finalize solutions
Implement solutions
