Introduction to Lean 6 Sigma Flashcards
What is the core concept of 6 Sigma?
Reducing Variation using data driven processes and decisions
Define 6 σ
Statistical representation for what many experts call “perfect”. A 6 Sigma process means there are only 3.4 defects per million opportunities.
How to calculate Sigma Level
(# Opportunities - # Defects) / ( # Opportunities)
What are common Six Sigma Principles
- Customer focused improvement
- Continuous Process Improvement
- Variation
- Removing Waste
- Equipping People
- Controlling the Process
Challenges of Six Sigma
- Lack of support
- Lack of resources and knowledge
- Poor project execution
- Data access issues
- Concerns about using six sigma in a specific industry
What does DMAIC stand for?
D = Define
M = Measure
A = Analyze
I = Improve
C = Control
What is Jidoka?
Principle that creates control of defects inside of a business process
What are the core principles of Lean 6 Sigma***
- Defining customer values
- Identifying the value stream for customer needs and desires
- Identifying waste in the process
- Creation of a continuous process flow
- Continually working to reduce the number of steps and time it takes to reach customer satisfaction
When to use Six Sigma?
- When facing the unknown
- When problems are widespread and not defined
- When costs are closely tied to the process
The 7(8) Muda
DOWNTIME
D:efects
O:verproduction
W:aiting
N:on used Talent
T:ransportation
I:nventory
M:otion
E:xcessive processing
Other:
Ideas
Cash
Type 1 Muda
Non-value-added tasks that are essential or required by circumstance
Type 2 Muda
Non-value-added tasks that are not essential.
What part of DMAIC is 5S Used
In the improve phase
What are the 5S?
- Sort
- Straighten
- Shine
- Standardize
- Sustain
What part of DMAIC is JIT Manufacturing concept used?
In the improve phase
What does JIT Manufacturing Mean
JIT is a lean concept meaning “Just-in-time”. Or - as needed by the customer.
What is Standard Deviation
Statistical measure to understand variation in a process
How to find standard deviation
What is the Pareto Principle
80% of the consequences come from 20% of the causes
What is VOC
Voice of customer
DPMO
Defects per fillion opportunities
DPMO = (Defects / Opportunities for defect) * 1,000,000
DPU
Defects per unit
Defects found in Sample /
# Units in Sample
FTY
First Time Yield
Good Units Producted /
# Of units entering the Process
RTY
Rolled Throughput Yield
(# units entering - (scrap - rework)) / # units entering)
A low RTY Indicates
there is waste in the process in the form of rework
DPU Provides:
An average level of quality
When to Use 5 Whys
In Analyze Phase, - good way to validate y = f(x) assumption
What is the problem statement checklist
Where?
When?
What?
How is it measured?
How much is the problem costing?
