Improve Phase Flashcards
What are all of the techniques used in the Improve phase?
- benchmarking for performance target
- brainstorming techniques to generate creative solutions
- moving towards continuous flow of materials or information
- design for manufacturability to improve process capability
- power and simplicity of error proofing
- corrective action matrix
What is design for sigma and what are the roadmaps?
Methodology used for heavy design orientation in process improvement
- DCDOV: define concept design optimize verify
- CDOV concept design optimize verify
- Dmadv: define measure analyze design
- DMADOV: define measure analyze design optimize verify
- Idov identify design optimize validate
- Iddov identify define design optimize verify
- Dccdi define customer concept design implement
- Dmedi define measure explore design implement
What is 1 principle of a dfm/ Dfss design?
Minimize the part count (step count). Each part/ tool brings its own opportunities for defect and assembly errors etc. the probability of producing a perfect part decreases exponentially as the number of parts increases because of potential for error propagates. Strategies to reduce the part count include combining functions into one part or selecting a common part from parts that perform similar functions.
What’s principle #8 of dfm/ ?dfss?
Error proof processes and improve part orientation through designs
- provide positive locating features so that parts can only be assembled one way
What is the difference between DMAIC and DMADV?
DMAIC - define measure analyze improve control is meant for process improvement for an existing process that isn’t meeting customer specification or isn’t performing.
Dmadv- define measure analyse design verify is used for when a new process needs to be implemented
Improved process has been optimized and still doesn’t meet the level of customer specification or lean six sigma level
What is benchmarking?
Process of developing new performance targets and standards for your process based on a comparison to other processes (example to a competitor). You should only benchmark with operations that perform better.
Benchmarking helps communicate to internal team members who may not have an external focus
Examples:
- company publications
- industry publications & trade journals
- 3rd party studies
- public financial reports
- tear downs
- books
What is brainstorming?
Team centered process used to generate new and hopefully creative ideas to solve a problem. It’s meant to encourage crazy ideas, be creative, suspend criticism and generate as many ideas as possible
What is seeding in brainstorming?
Seeing is telling participants about the problem one or two days in advance of the scheduled session. It allows the team to consider the possibilities more thoroughly and as result, bring a higher number of more creative ideas to the party.
What is negative brainstorming?
It’s thinking “what are the things we would do if we wanted to fail for sure”. How many of these things are we doing now?
It’s meant to show quick hitters - things we should stop doing ASAP. (Example - an affinity diagram)
What are 4 steps for brainstorming?
- Lay out the problem you want to solve.
- Identify the objectives of the possible solution.
- Try to generate solutions individually, people do it separately
- Once you’re done with 1-3, work as a group
What’s a creative way to approach brainstorming?
- Negative brainstorming
- Brainstorm to come up with questions, not answers - encourage people to formulate lots of questions around the issue or problem and lead to deeper analysis and a better understanding of that problem.
How to conduct multivoting for brainstorming?
- Generate a list of ideas using a method such as brainstorming.
- Assign a letter to each idea to minimise confusion.
(3a Assign how many people anyone can give)
(3b Vote: can be private or public) - Repeat until the list reduced to desired number (max 5 recommended)
What is FMEA?
Failure Mode and Effects Analysis- tool used to prioritize potential defects based on their severity, expected frequency and likelihood of detection. It can be performed on a design or a process - it’s used to prompt actions to improve design or process robustness.
What are the categories in a matrix of fmea?
- severity: the seriousness of a failure mode
- Occurance: the likelihood that it will happen again
- detection: likelihood that a given failure mode will be detected if it occurs prior to release to customer
Risk priority number - rpn.
