Introduction to Lean 6 Sigma

Question 1

What is the core concept of 6 Sigma?

Answer 1

Reducing Variation using data driven processes and decisions

Question 2

Define 6 σ

Answer 2

Statistical representation for what many experts call “perfect”. A 6 Sigma process means there are only 3.4 defects per million opportunities.

Question 3

How to calculate Sigma Level

Answer 3

(# Opportunities - # Defects) / ( # Opportunities)

Question 4

What are common Six Sigma Principles

Answer 4

1. Customer focused improvement
2. Continuous Process Improvement
3. Variation
4. Removing Waste
5. Equipping People
6. Controlling the Process

Question 5

Challenges of Six Sigma

Answer 5

1. Lack of support
2. Lack of resources and knowledge
3. Poor project execution
4. Data access issues
5. Concerns about using six sigma in a specific industry

Question 6

What does DMAIC stand for?

Answer 6

D = Define
M = Measure
A = Analyze
I = Improve
C = Control

Question 7

What is Jidoka?

Answer 7

Principle that creates control of defects inside of a business process

Question 8

What are the core principles of Lean 6 Sigma***

Answer 8

1. Defining customer values
2. Identifying the value stream for customer needs and desires
3. Identifying waste in the process
4. Creation of a continuous process flow
5. Continually working to reduce the number of steps and time it takes to reach customer satisfaction

Question 9

When to use Six Sigma?

Answer 9

1. When facing the unknown
2. When problems are widespread and not defined
3. When costs are closely tied to the process

Question 10

The 7(8) Muda

Answer 10

DOWNTIME

D:efects
O:verproduction
W:aiting
N:on used Talent
T:ransportation
I:nventory
M:otion
E:xcessive processing

Other:
Ideas
Cash

Question 11

Type 1 Muda

Answer 11

Non-value-added tasks that are essential or required by circumstance

Question 12

Type 2 Muda

Answer 12

Non-value-added tasks that are not essential.

Question 13

What part of DMAIC is 5S Used

Answer 13

In the improve phase

Question 14

What are the 5S?

Answer 14

1. Sort
2. Straighten
3. Shine
4. Standardize
5. Sustain

Question 15

What part of DMAIC is JIT Manufacturing concept used?

Answer 15

In the improve phase

Question 16

What does JIT Manufacturing Mean

Answer 16

JIT is a lean concept meaning “Just-in-time”. Or - as needed by the customer.

Question 17

What is Standard Deviation

Answer 17

Statistical measure to understand variation in a process

Question 18

How to find standard deviation

Answer 18

Question 19

What is the Pareto Principle

Answer 19

80% of the consequences come from 20% of the causes

Question 20

What is VOC

Answer 20

Voice of customer

Question 21

DPMO

Answer 21

Defects per fillion opportunities

DPMO = (Defects / Opportunities for defect) * 1,000,000

Question 22

DPU

Answer 22

Defects per unit

Defects found in Sample /
# Units in Sample

Question 23

FTY

Answer 23

First Time Yield

Good Units Producted /
# Of units entering the Process

Question 24

RTY

Answer 24

Rolled Throughput Yield

(# units entering - (scrap - rework)) / # units entering)

Question 25

A low RTY Indicates

Answer 25

there is waste in the process in the form of rework

Question 26

DPU Provides:

Answer 26

An average level of quality

Question 27

When to Use 5 Whys

Answer 27

In Analyze Phase, - good way to validate y = f(x) assumption

Question 28

What is the problem statement checklist

Answer 28

Where?
When?
What?
How is it measured?
How much is the problem costing?