Introduction

Question 1

Overall Equipment Effectiveness (OEE)?

Answer 1

Rate (% of max) x Availability (% of time) x Quality (% right first time)

Question 2

Operational Excellence is absolute or relative?

Answer 2

Absolute

Question 3

What is lean thinking?

Answer 3

Lean thinking is about accelerating the velocity of any process by doing only the things that add customer value and eliminating other activities that don’t (waste)

Question 4

Origins of Lean

Answer 4

Autonomy/ no errors forward
Forms of waste
Production Levelling
Continuous Improvement

Question 5

Lean Principles

Answer 5

Identify Value
Map Value Stream
Create Flow
Establish Pull
Pursue Perfection

Question 6

Focus of traditional improvement programs

Answer 6

Work Longer
Work Harder
Add People
Add Equipment

Question 7

Lean is not about eliminating people…

Answer 7

It is about continuous process improvement, NOT cost reduction through headcount cutbacks

Question 8

What is Six Sigma

Answer 8

Vision 
Business Strategy
Goal 
Metric
Benchmark
Philosophy 
Vehicle for Business Excellence
(Continuous Improvement methodology aimed at reducing and eliminating variation in processes, resulting in financial savings and improved customer satisfaction.)

Question 9

Goal of Six Sigma

Answer 9

Reduce and Control variation in processes

Reduce defects
Increase Yield
Improve Customer Satisfaction
Higher Profit

Question 10

Six Sigma Approach

Answer 10

Practical Problem
Statistical Problem
Statistical Solution
Practical Solution

Question 11

Achieving Six Sigma Performance

Answer 11

Understanding Customer Needs
Simplifying Processes
Reducing Variation

Question 12

DMAIC

Answer 12

Define, Measure, Analyse, Improve, Control

Question 13

What makes Six Sigma successful?

Answer 13

1) Focus on Customers (VoC)
2) Integrates human and process aspects
3) Uses a disciplined approach to problem solving (DMAIC)
4) Organisational Project Infrastructure
5) Active Senior Management leadership and Commitment
6) Significant bottom line financial returns
7) Effective use of statistics
8) Data driven methodology
9) Focuses of solution unknown problems

Question 14

Six Sigma Ranks

Answer 14

Champion
Master Black Belts
Black Belts
Green Belts 
Yellow Belts

Question 15

Lean vs Six Sigma

Answer 15

Lean - High Value High cost
Six Sigma - Low Value Low Cost
LSS - COMBO

Question 16

Lean focuses on …

Answer 16

Dramatically improving flow in the value stream and eliminating waste

Question 17

Lean aims

Answer 17

Elimination of waste
Identification of value stream 
Achievement of flow
Pacing by pull
Pursuit of perfection

Question 18

Lean outcome

Answer 18

improved speed

Question 19

Six Sigma focuses on…

Answer 19

eliminating defects and reducing variation in processes

Question 20

Six Sigma aims

Answer 20

DMAIC

Question 21

Six Sigma Outcomes

Answer 21

Reduced Variation

Question 22

Lean and Six Sigma Similarities

Answer 22

Same Objective: continuous and sustainable business process improvement
Focus on business needs defined by the customer
Customer focus
Requires active involvement of all interested
Practical methods, proven to work
Both include a comprehensive tool box improve any business process

Question 23

Lean vs Six Sigma differences

Answer 23

Lean
Focused on flow
Removal of waste
Technically simple
Low investment
Typically non statistical tools
Appropriate for first round of improvements

Six Sigma
Focused on problems with unknown solution
Reduction of defects often through reduction of variation
Technically more difficult
More significant investment
Statistical tools typically used
Appropriate for more complex problems