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Lean Six Sigma > Key Terms and Definitions > Flashcards

Key Terms and Definitions Flashcards

1
Q

What is LSS?

A

LSS is a business strategy of creating and sustaining value for the customer by identifying value streams and eliminating waste.

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2
Q

3 Benefits of LSS

A

1) Improve Quality
2) Reduce Costs
3) Save Time (Reduce Leadtime)

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3
Q

LSS Key to Success

A

Buy in from everyone.

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4
Q

Who Developed Lean

A
  • Toyota (real name Toyoda)
  • Also know as Toyota Production System (TPS)
  • Taiichi Ohno: Father of Lean
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5
Q

When Was Lean Created / Popular

A
  • Created: Post WWII

- Popular: mid 90’s

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6
Q

Who Developed Six Sigma

A
  • Motorola
  • Bill Smith
  • SPC applied to quality
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7
Q

When Was Six Sigma Created / Popular

A
  • Created: Mid-80s

- Popular: GE; Jack Welch; Created Belt Colors

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8
Q

What did Vilfredo Pareto Introduce?

A
  • Pareto Chart
  • 80/20 Principle
    • 20% of the effort = 80% of the results
    • 20% of the causes = 80% of the effects
    • Focus on the significant few vs instead of the insignificant many
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9
Q

What did Henry Ford Introduce?

A

The assembly line.

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10
Q

What did Walter Shewhart Introduce?

A

Special cause and common cause variation

  • Special cause: abnormal
  • Common cause: explainable

Developed Plan-Do-Check-Act (PDCA) method of problem solving.

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11
Q

What did Fredrick Taylor Introduce?

A

There’s one best way to do it

- standardized processes

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12
Q

What did W. Edward Deming Introduce?

A

Went to Japan and introduced:

Total Quality Management

  • SOPs: standard operating procedures
  • SPC
  • Control Charts

Considered: Father of Quality

“Quality is everyone’s responsibility.”

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13
Q

What did Dr. Kaora Ishikawa Introduce?

A

Fishbone Diagram
- Also known as Cause and Effect Diagram

Diagram Design
- Head of Fish: Ultimate Problem
- Typically 6 Bones: Manpower, Material, Machine,
Method, Measurement, Management
- Start a the End of each fishbone (current state) and
work towards the spine
- Ask WHY until no longer can to reach root cause
- Ask THEREFORE, working back towards the outer
portion of the bone

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14
Q

What did Shigeo Shingo Introduce?

A

Poka-Yoke

  • mistake proofing
  • preventing an error from occurring
Soft = message only
Hard = will prevent from occurring
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15
Q

What did Taiichi Ohno Introduce?

A

Muda

  • 7 types of waste +1
  • waste = non-value added steps in process
T = Transportation
I = Inventory (excessive hides problems or defect)
M = Motion
W = Waiting
O = Over Production
O = Over Processing (unnecessary processing) 
D = Defects
\+1 = Unused Employee Creativity
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16
Q

What is the Toyota House of Quality?

A

Foundation (Stability)

  • Heijunka (leveling of production)
  • Standardized Work
  • Kaizen

Pillars

  • Left: Jidoka (stop the line; automation with a human touch)
  • Right: JIT

Roof

  • I = Improved Quality
  • R = Reduced Costs
  • S = Saves Time (reduce leadtime)
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17
Q

What is the Toyota Way House?

A

Pillars

  • Left: Continuous Improvement
  • Right: Respect for People
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18
Q

What is Value?

A

Customer determines value

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19
Q

What is value added for goods?

A

Something that changes the shape or form of a product that the customer is willing to pay for

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20
Q

What is a Value Stream for Goods?

A

From the time the customer places order until the time the customer received the product..

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21
Q

?

A

?

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22
Q

How is Value Achieved?

A

Done across processes (cross functionally) instead of done by a department (functionally)

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23
Q

?

A

?

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24
Q

What are the 3 levels of value streams from start to stop?

A

1) Process
2) Door to Door (factory / get to until leave hospital
3) Enterprise (getting sick until complete recovery)

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25
Q

?

A

?

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26
Q

What is process mapping?

A
  • Showing from process to process.
  • Also known as flowcharting.
  • Uses symbols and decisions
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27
Q

What is value stream mapping?

A

Articulates the flow of material and information into and out of processes.

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28
Q

What are the benefits of value stream mapping?

A

Benefits:

1) (Gemba) Seeing where the work happens
2) Quickly identifies waste
3) Understanding materials and information flow

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29
Q

What are the 2 types?

A

1) Current state

2) Future state

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30
Q

?

A

?

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31
Q

How is value stream mapping done?

A
  • Involves everyone
  • If possible, organize chronologically

1) Start with start / stop points
2) Add process boxes

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32
Q

?

A

?

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33
Q

What is the order value stream mapping is done?

A

1) Processes
- stated in verb and nouns

2) Connectors
- Arrows between boxes
- Either push or pull arrows

3) Symbols
- See handout

4) Data Boxes
5) VA / NVA time

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34
Q

?

A

?

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35
Q

What is a data box?

A

Box to illustrate and show data relevant to the process of a value stream

Contains

  • Time:
  • Processing, wait, cycle
  • Quality
  • Number or % of defects or rejects
  • Inventory
  • How much? Costs/Expenses, Revenue
  • Resources
  • # of people
  • space
  • distance traveled
  • Yield: how many
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36
Q

?

A

?

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37
Q

What is change over time?

A

Period of time to prepare a device, machine, process or system to change from producing the last good piece of the last batch to processing the first good piece of the new batch.

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38
Q

?

A

?

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39
Q

What is SMED?

A

Single minute exchange of die

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40
Q

What is TAT?

A

Turn around time

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41
Q

?

A

?

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42
Q

What is Takt time?

A

available time / customer demand

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43
Q

?

A

?

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44
Q

How to improve Takt time?

A

?

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45
Q

?

A

?

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46
Q

What is Kaizen?

A

Kai (change) zen (good)

continuous improvement

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47
Q

Process improvement Function

A

f(x) = y + E

f = Process
x = Input
y = Output
E = Error
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48
Q

?

A

?

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49
Q

What are the types of waste?

A
  • Muda
  • Muri
  • Mura
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50
Q

What is Muda?

A

Muda

  • 7 types of waste +1
  • waste = non-value added steps in process
T = Transportation
I = Inventory (excessive hides problems or defect)
M = Motion
W = Waiting
O = Over Production
O = Over Processing (unnecessary processing) 
D = Defects
\+1 = Unused Employee Creativity
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51
Q

?

A

?

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52
Q

What is Muri?

A

Overburdening a person or machine

53
Q

?

A

?

54
Q

What is Mura?

A

Unevenness in the work-flow

  • Can be caused by batch processing
  • Improve using Heijunka (leveling)
55
Q

?

A

?

56
Q

What is Heijunka?

A

Leveling

  • maintaining a static work-load avoiding dramatic
    shifts or swings in production
  • Level: start at the beginning of the value stream (the first process?)
57
Q

?

A

?

58
Q

How is Heijunka improved?

A
  • One piece flow processing instead of batch and que
    processing
  • Push vs Pull
  • FIFO
59
Q

?

A

?

60
Q

What is batch processing?

A 
-Dedicated work stations designed for a specific work 
 function
- comparison is an elevator
61
Q

?

A

?

62
Q

What is One Piece Flow?

A
  • completing the production or service from start to finish with as little inventory as possible between tasks (steps)
  • a collection of work cells
  • comparison is an escalator
63
Q

?

A

?

64
Q

What is push?

A

?

65
Q

?

A

?

66
Q

What is pull?

A
  • Create pull by starting at the end of the value stream
  • Identify and eliminate constraint (bottleneck). Move upstream, to the next constraint and eliminate…
  • This is kaizen; establishing a standard and improving through kaizen event, establish new standard
67
Q

?

A

?

68
Q

What is FIFO?

A
  • First in first out

- introduce FIFO at the beginning of the value stream

69
Q

?

A

?

70
Q

FIFO and XOXO

A 
X = heavy workload
O = light workload

Mix XO to Heijunka (creates leveling)

71
Q

FIFO avoids?

A
  • Obsolescence
  • Poor customer satisfaction
  • Aging material
  • Decay-
72
Q

?

A

?

73
Q

What is 5S?

A

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

74
Q

What is sort?

A

Clearly distinguish needed items from unneeded and eliminate the latter

75
Q

What is straighten?

A

Keep needed items in the correct place to allow for easy and immediate retrieval

76
Q

What is shine?

A

Keep the workplace neat and clean

77
Q

What is standardize?

A

The method by which sort, straighten and shine are made habitual

78
Q

What is sustain?

A

Maintain established procedures

79
Q

?

A

?

80
Q

Why do / benefits of 5s?

A

Safety, Reduce Waste and Clutter

81
Q

?

A

?

82
Q

What are ergonomics?

A

Fitting the workplace for the people

83
Q

?

A

?

84
Q

What is motion economy?

A

Seeks to eliminate, combine, reduce and smooth motion

  • Considers the workplace arrangement
  • Placement of tools, supplies, and equipment to
    minimize motion
85
Q

?

A

?

86
Q

Why standards / standardization?

A

Necessary for:

  • reduce variation
  • Training
  • Auditing
  • Improvement
87
Q

?

A

?

88
Q

Why auditing

A

Accountability
- Kamishibai = audit board

  • Process Metric
  • Outcome Metric
89
Q

?

A

?

90
Q

Taiichi Ohno - Standards

A

Without standards, continuous improvement isn’t possible.

91
Q

?

A

?

92
Q

How to document SOPs

A

Time, Materials, Work Sequence

93
Q

?

A

?

94
Q

What is work sequencing?

A

Individual work steps; usually only consists of a verb and noun

95
Q

?

A

?

96
Q

What is the process for a kaizen or a rapid improvement event?

A

Create standard then kaizen (continuous improvement)…establish new standard then kaizen…

97
Q

?

A

?

98
Q

What is TWI?

A

Training within industry

  • Methodology developed during WWII
99
Q

?

A

?

100
Q

What’s JIT and how does it work?

A

JIT = Just in Time
- materials when needed; in the quantities needed

  • Based upon pull systems of production determined
    by customer
  • Requires production scheduling based on the needs
    of the customer
  • Supplies delivered only when needed
101
Q

?

A

?

102
Q

What’s a Kanban?

A

Kanban is used to signal low levels of inventory

  • Signal of some kind: Sign, signboard, doorplate,
    poster, billboard, card
103
Q

?

A

?

104
Q

Why visual management?

A
  • Manage what you want to make visual
  • Don’t have to communicate verbally

Example: Andon Light

105
Q

?

A

?

106
Q

What is Jidoka?

A
  • Automation with a human touch
  • Stop when something goes wrong

example: Andon Light

107
Q

?

A

?

108
Q

Zero Defects are Possible

A
  • Never accept a defect
  • Never create a defect
  • Never pass a defect
109
Q

?

A

?

110
Q

What’s Poka-Yoke?

A

Poka (mistake) - Yoke (proofing)

- preventing an error from occurring

111
Q

?

A

?

112
Q

What are the types of Poka-Yoke?

A

Soft: visual only
Hard: will prevent from occurring

113
Q

?

A

?

114
Q

Tools to identify root cause

A
  • 5 why
  • Pareto Chart
  • Cause and effect (Fishbone)
115
Q

?

A

?

116
Q

What is a problem?

A

Deviation from standard

117
Q

?

A

?

118
Q

Lean problem solving methodology

A

Plan-Do-Check-Act (PDCA)

119
Q

PDCA - Benefits / Drawbacks

A

Benefits: quick
Drawbacks: less scientific

120
Q

?

A

?

121
Q

Six Sigma problem solving methodology

A

Define-Measure-Analyze-Improve-Control (DMAIC)

122
Q

DMAIC - Benefits / Drawbacks

A

Benefits: scientific
Drawbacks: takes longer

123
Q

What’s an A3?

A

A size of a piece of paper (about a legal size)

  • Toyota uses for problem solving
  • Information all on one side of paper
  • Left side what
  • Right side how
124
Q

?

A

?

125
Q

What are SMART goals?

A 
S = Specific
M = Measurable
A = Agreed to
R = Realistic
T = Time bound
126
Q

?

A

?

127
Q

What is Gemba?

A

The place where the value is created

- where the working is occurring (shop floor) and value is added

128
Q

Purpose of Gemba?

A
  • Go see
  • Ask why
  • Show respect
129
Q

What is Genchi Genbutsa?

A
  • Personal involvement

- Learn by doing

Lean Six Sigma (3 decks)

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