Improvement

Question 1

What is the difference between DMAIC and DMADV?

Answer 1

DMAIC is for an existing process whereas DMADV is setting up a new process. DMADV covers design and validate at the end instead.

Question 2

What is DMAIC?

Answer 2

Define
Measure
Analyse
Improve
Control

Question 3

What do you do during the define stage in DMAIC?

Answer 3

1. Define the problem statement
2. Identify the team that will work on the project
3. Gather the Voice of customer (VOC) and Critical to Quality (CTQ) - I.e what is most important to the customer
4. Create the SIPOC - scope the project - identifying stakeholders required
5. Create business case or project charter -

Question 4

What is a project charter?

Answer 4

One page document that covers milestones, what you are trying to achieve, team members.

This is used by green belt. Black belt produce the business case.

Question 5

What happens during the measure phase?

Answer 5

1. Identify the as/is or current state or baseline - NOW
2. Plan AND collect the data - to understand how the process is NOW

Question 6

What is important to remember about the measure phase?

Answer 6

Anything that presents the current/as is or baseline process is always the measure phase

Question 7

What do you do during the analyse phase?

Answer 7

1. You review the data gathered during measure on NOW phase by producing the root cause analysis (RCA) = fish bone 5 whys
2. Identify solutions to help eliminate the problem statement identified during define phase
3. Define to be state/future state

Question 8

What happens during the improve stage?

Answer 8

1. Implement the solution - pilot process
2. Create the control plan

Question 9

What happens during the control phase?

Answer 9

Sustain the gains - make sure they don’t go back to the old process

Question 10

Are there reviews between each DMAIC phase?

Answer 10

Yes - gate reviews

Question 11

What is 3C?

Answer 11

1. Concern - what is the problem? (Define phase in DMAIC)
2. Cause - what is the cause of this problem and identify solution (Analyse phase in DMAIC)
3. Correct - implement and maintain (improve phase in DMAIC) the implementation (control phase in DMAIC)

Question 12

What is the point in using the 3c?

Answer 12

For simple projects where you don’t need to do a lot of analysing and measuring.

Question 13

What are the 8 D’s?

Answer 13

Disciplines.

1. Establish team
2. Describe problem
3. Develop an interim containment action (temporary fix)
4. Define/verify root cause
5. Choose/verify permanent corrective action
6. Implement validate permanent corrective action
7. Prevent recurrence
8. Recognise team

Question 14

What is the difference between DMAIC and the eight D’s?

Answer 14

It is about creating an early temporary solution and also recognise the team at the end.

Question 15

What are the PCDA steps?

Answer 15

Plan - develop a plan to address problem or hypotheses, identify control points, review and agree.

Do - plan is carried out.

Check - info is collected on parameters and actual results are compared to what was expected.

Act - results are analysed, differences between expected and actual results are identified and discussed and agreed. Corrective action is identified that triggers another cycle (back to plan).

Question 16

What is Kaizen?

Answer 16

Improving something even if it isn’t broken to compete with competitors. The goal is not a 100% solution that solves all problems at one time, rather than a 70% solution accomplished in a few days using a simple, low cost, low tech tools. Everyone takes part. Small incremental steps. Formal Kaizen builds on Kaizen bursts defining a formal framework.

Question 17

How long should a Kaizen burst last?

Answer 17

Max 2-3 hours

Question 18

How long should a Kaizen event last?

Answer 18

No more than 5 days

Question 19

What is the Kaizen process?

Answer 19

Preparation - 1 month
Pre-Kaizen - up to 2 days
Implementation - 2 to 5 days
Follow up - up to 1 month

Question 20

Who identifies the waste during the preparation phase of the Kaizen process?

Answer 20

Management team

Question 21

Must you do a pre-kaizen during the formal kaizen process?

Answer 21

No - it is optional and only used during longer kaizen bursts.

Question 22

Is the follow up phase mandatory in a formal kaizen process?

Answer 22

Optional - used in longer kaizens or where solution can’t be completed within the timeframe. Some team members are working part time on this.

Question 23

When do you not do a kaizen?

Answer 23

Short time scale, when rigorous stat analysis and data gathering is required or when the changes need to be effectively project managed like where are large amounts of business risk.

Question 24

If a company is concerned about poor performance of something but they don’t know how bad the problem is. What method is most appropriate?

Answer 24

DMAIC as there will need to be data gathering.

Question 25

What method is appropriate if there is a problem with a specific part of the process and they know what the problem is?

Answer 25

3 C as you don’t need lots of data

Question 26

What is a distribution curve?

Answer 26

It is where you plot all your data (distribution) on a chart and it is represented in a curve as it is in order of smallest at the front and back and then highest in the middle. 50% of your data falls on the left hand side and 50% on the right side.