Intro

Question 1

What is the principle of six sigma?

Answer 1

To provide reliable, consistent, dependable products to customers

Question 2

What does six sigma focus on?

Answer 2

Defects, variability, the customer

Question 3

How can six sigma methods be applied?

Answer 3

The methods can be applied to reduce variability in a transportation department to improve on time delivery

Question 4

What is the purpose of Lean?

Answer 4

To eliminate waste (non-value added activities)

Question 5

What are examples of waste?

Answer 5

Unnecessary steps/activities, rework, waiting time

Question 6

What is the goal of lean?

Answer 6

To find waste and permanently eliminate it

Question 7

What does lean do?

Answer 7

Streamlines processes (addresses physical problems)

Question 8

What is six sigma?

Answer 8

Six sigma reduces defects (addresses, variability/performance caused by errors and defects)

Question 9

What are the six sigma steps?

Answer 9

Define, measure, analyze, improve, control (DMAIC)

Question 10

What is determined in the define phase?

Answer 10

What the project is, and what it should accomplish

Question 11

What are some key tools applied in the define stage?

Answer 11

Conduct process mapping (what the project entails), outline, expected, accomplishments, develop financial measurements, define the problem

Question 12

What are the two aspects of measurement?

Answer 12

What to measure, how to measure (must know what questions you want to answer to determine what type of data you need to collect)

Question 13

What mathematical expression is used?

Answer 13

Y=f(x), f:function, x:input, y:output

Question 14

What tools are used in the Measure step?

Answer 14

Data collection, cause-and-effect diagram (fish bone), process mapping, Valley Stream mapping, process, control charts, process capability charts, histograms, Pareto charts

Question 15

What is the analyze process?

Answer 15

Understanding why you are having this problem

Question 16

What is something you must understand before analyzing?

Answer 16

How the existing process works and how the process should work.

Question 17

What tool can you use for analyzing?

Answer 17

Process mapping (consider time, cost, yield, capacity)

Question 18

When analyzing a process map, what should you look for?

Answer 18

• time traps (activities slowing down process)
• find areas to eliminate complexity

Question 19

Review data collected from:

Answer 19

Control charts, capability charts, histograms, Pareto charts (seek out trends to find problem areas)

Question 20

What is the immortal important tool to master?

Answer 20

The 5 whys technique

Question 21

What are some additional tools for analyzing?

Answer 21

• Scatter plots (determined if there’s a relationship between two variable)
• Time series graphs, analysis of variance

Question 22

What tools are used in the improve stage?

Answer 22

Brainstorming and communication

Question 23

What is an effective method to ease the resistance to change?

Answer 23

• recognize employees being affected by getting them involved early
• have support of process owner
• follow good project management techniques in the improve stage

Question 24

What are the keys to success in the improve stage?

Answer 24

Brainstorming, communication, and implementing

Question 25

What is the most important step in the DMAIC methodology?

Answer 25

Control (it enables you to have a continuous improvement organization)

Question 26

What is done in the control phase?

Answer 26

Tools and procedures are put in place to ensure solution is maintained

Question 27

What are some control examples?

Answer 27

- checklists - monthly review meeting - document updates - training

Question 28

What are some effective monitoring systems?

Answer 28

- mistake prevention ( implement procedures to prevent mistakes) - mistake proofing (correcting mistakes)

Question 29

What’s the design for 6 sigma methodology?

Answer 29

- DMADV (Define, Measure, Analyze, Design, Verify) - Focuses more on the final customer using VOC

Question 30

What are the 5 key lean principles?

Answer 30

- 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)

Question 31

What is a key tool of the Lean Philosophy?

Answer 31

Process mapping (flow of activities, helps distinguish value vs non-value activities)

Question 32

What are some Lean limitations?

Answer 32

Lean is not based on statistics

Question 33

What are Lean manufacturing metrics?

Answer 33

- Improved customer service - Better use of resources - Reduced Inventories - Higher product quality

Question 34

What are the 5 S’s of organizing in Lean?

Answer 34

- 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)

Question 35

What is a Lean expression?

Answer 35

Kaizen: gradually and orderly continuous improvement

Question 36

What is Kaizen Blitz?

Answer 36

Expedited improvements made under tight deadlines

Question 37

What are three things needed to be successful?

Answer 37

- Leadership from the top ( must support) - Skilled team members - Supporting infrastructure

Question 38

What are the benefits of lean 6 sigma?

Answer 38

- helps reduce complexity (variability adds cost, time, and waste)