Intro Flashcards
What is the principle of six sigma?
To provide reliable, consistent, dependable products to customers
What does six sigma focus on?
Defects, variability, the customer
How can six sigma methods be applied?
The methods can be applied to reduce variability in a transportation department to improve on time delivery
What is the purpose of Lean?
To eliminate waste (non-value added activities)
What are examples of waste?
Unnecessary steps/activities, rework, waiting time
What is the goal of lean?
To find waste and permanently eliminate it
What does lean do?
Streamlines processes (addresses physical problems)
What is six sigma?
Six sigma reduces defects (addresses, variability/performance caused by errors and defects)
What are the six sigma steps?
Define, measure, analyze, improve, control (DMAIC)
What is determined in the define phase?
What the project is, and what it should accomplish
What are some key tools applied in the define stage?
Conduct process mapping (what the project entails), outline, expected, accomplishments, develop financial measurements, define the problem
What are the two aspects of measurement?
What to measure, how to measure (must know what questions you want to answer to determine what type of data you need to collect)
What mathematical expression is used?
Y=f(x), f:function, x:input, y:output
What tools are used in the Measure step?
Data collection, cause-and-effect diagram (fish bone), process mapping, Valley Stream mapping, process, control charts, process capability charts, histograms, Pareto charts
What is the analyze process?
Understanding why you are having this problem
What is something you must understand before analyzing?
How the existing process works and how the process should work.
What tool can you use for analyzing?
Process mapping (consider time, cost, yield, capacity)
When analyzing a process map, what should you look for?
- time traps (activities slowing down process)
- find areas to eliminate complexity
Review data collected from:
Control charts, capability charts, histograms, Pareto charts (seek out trends to find problem areas)
What is the immortal important tool to master?
The 5 whys technique
What are some additional tools for analyzing?
- Scatter plots (determined if there’s a relationship between two variable)
- Time series graphs, analysis of variance
What tools are used in the improve stage?
Brainstorming and communication
What is an effective method to ease the resistance to change?
- recognize employees being affected by getting them involved early
- have support of process owner
- follow good project management techniques in the improve stage
What are the keys to success in the improve stage?
Brainstorming, communication, and implementing
What is the most important step in the DMAIC methodology?
Control (it enables you to have a continuous improvement organization)
What is done in the control phase?
Tools and procedures are put in place to ensure solution is maintained
What are some control examples?
- checklists
- monthly review meeting
- document updates
- training
What are some effective monitoring systems?
- mistake prevention ( implement procedures to prevent mistakes)
- mistake proofing (correcting mistakes)
What’s the design for 6 sigma methodology?
- DMADV (Define, Measure, Analyze, Design, Verify)
- Focuses more on the final customer using VOC
What are the 5 key lean principles?
- Determine the value (determine performance metrics)
- Identify the value stream (process mapping)
- Make value flow without interruptions
- Allow the customer to pull value (only produce to satisfy customer demand)
- Pursue perfection (continuous improvement)
What is a key tool of the Lean Philosophy?
Process mapping (flow of activities, helps distinguish value vs non-value activities)
What are some Lean limitations?
Lean is not based on statistics
What are Lean manufacturing metrics?
- Improved customer service
- Better use of resources
- Reduced Inventories
- Higher product quality
What are the 5 S’s of organizing in Lean?
- Sort (ensure item is in its proper place)
- Set in order (arrange materials/tools for proper access)
- Shine (Keep work area clean)
- Standardize (establish procedures to ensure all steps are performed correctly)
- Sustain (continue process through training/communication)
What is a Lean expression?
Kaizen: gradually and orderly continuous improvement
What is Kaizen Blitz?
Expedited improvements made under tight deadlines
What are three things needed to be successful?
- Leadership from the top ( must support)
- Skilled team members
- Supporting infrastructure
What are the benefits of lean 6 sigma?
- helps reduce complexity (variability adds cost, time, and waste)
