KNOWLEDGE CHECK Flashcards
Complete the following statement: The Phase Model
… serves to prepare several people in a larger specialist area for the various KATA roles and to start implementing them.
Which of the following statements apply to the comfort zone?
Target known
Method known
Route known
Sort the following terms with regard to their effect to the results. Place “results” at the bottom.
Leadership
Employees
Processes
Results
Which of the following statements apply to the learning zone?
Target known
Method known
Route unknown
Which of the following statements apply to the fear zone?
Target known
Method unknown
Route unknown
What are the characteristics of the following improvement approaches?
Expert-driven CIP
Improvement by a few experts
Employees are implementers
Learning not possible
Employee-driven CIP
Learning by dong
Employees are coached by managers
Improvement by many employees in the line
What is the correct order of the 5 coaching questions?
- What is the target condition?
- What is the current current condition?
- What obstacles are currently preventing us from achieving the target condition? What obstacle do you want to tackle now?
- What is your next step?
- When can we see what we have learned from this step?
What are the characteristics of the following improvement approaches?
Planned CIP
• Assumed general conditions: Constant
• Goal achievement path: Known
• Strategy: Planning and implementing known solutions
• Control system: Cyclical monitoring of progress of activity
Experimental CIP • Assumed general conditions: Variable • Goal achievement path: Unknown • Strategy: Small steps, PDCA loops • Control system: Short-cyclical coaching to ensure learning process, compliance with improvement corridor
What are the 4 roles in KATA?
- Employee
- Coach
- Improver
- 2nd Coach
What attitudes can a coach have towards his mentee?
external valuation – self-esteem • I'm OK – You're OK! external depreciation – self-esteem • I'm OK – You're not OK! external valuation – self-deprecation • I'm not OK – You're OK! external depreciation – self-deprecation • I'm not OK – You're not OK!
The PEW formula is short for …
perception - effect - wishes
What are the 3 coaching questions between coach and 2nd coach?
- What is your impression of the coaching cycle?
- What are you concentrating on for the next coaching cycle?
- What are my observations on the conversation?
Assign the following roles to their respective level of the Dreyfus model of skill acquisition.
Level 5
• Expert
Level 4
• Experienced practitioner
Level 3
• Practitioner
Level 2
• Advanced
Level 1
• Novice
Not part of the Dreyfus model of skill acquisition • Manager • Consultant • Teacher • Trainer • Employee
Which of the following characteristics are requirements for your house that can be used to evaluate quality?
Size
Amount of rooms
Color
Price
Amount of garages
If I woke you up at 3am you would tell me …
.. to identify a failure (lack of quality) is good
… to identify a failure as early as possible is cheaper
… to avoid a failure must be the main goal of quality improvement in my company
Which statement do you associate with quality and how?
Good quality
• I fulfill all my requirements I got from my customer!
• The house has just one room but I’m alone and I exactly need one room
Bad quality
• Last year we had 5000 claims because of a broken edge at our part!
• This steak is really nice but the price is really too high! And it was too small, I’m still hungry
• The house is green with water-protective color but I ordered a red one with standard color
No information about quality
• This new Mercedes has the new LED-spotlight technology with the best illumination you could imagine!
• The house has a size of 500 m².
• The price of the beach house is 1.5 Billion $ and I have direct access to the ocean
How can I check the “set of characteristics of a unit with respect to its suitability to satisfy specified and implied requirements”, on the example of my house?
folding ruler
• size
counting
• amount of rooms
• amount of garages
looking
• colour
contract
• price
What could be an advantage to move your organization from hierarchy based to process-/project-oriented in terms of quality and customer satisfaction?
Downsides of traditional organization concepts
• Functional isolation
• Coordination problems
• Conflicting priorities between departments
• Not enough customer orientation
Advantages of a process/project-oriented organization
• Customer focus
• Focus on project success instead of department success
If I talk about quality, I need to know the (1) and I need to check the (2).
- Characteristics
2. Customer Satisfaction
Which statements are correct? Setup of a QMS
The ISO 9001 drives the PDCA-Thinking.
Process and customer focus are a important focus of IATF 16949.
Top management shall demonstrate leadership and commitment with respect to the quality management system.
What possibilities do I have in a consulting project to check the effectiveness of my processes?
Carry out an internal process audit, identify and eliminate deviations.
Recording of process key figures such as lead time or process errors and verification of their development.
Checking the (number of) interfaces within processes.
Tick the boxes with which I can measure the effectiveness of my organization in terms of customer satisfaction.
Average lead time for customer orders
Number of errors at customer
Number of new customers
Number of regular customer
Assign the respective terms to a classic QMS or a TQS.
Classic QMS
• People make failures
• Individual employees are responsible for errors
• Zero failures are not feasible
• Parts procurement from many suppliers
• Customers must take what the company delivers in terms of quality
TQS
• Processes provoke errors
• All employees are responsible for errors
• Zero failure is the goal
• Partnership with a few suppliers
• Everything is geared towards complete customer satisfaction
Reflection on quality, detection of failures and avoidance of failures: Which statements are correct?
The type of organization has a significant impact on my quality.
ISO 9001 includes the logic of continuous improvement with PDCA.
There are industry-specific standards according to which I can align my QMS. For automotive this is the IATF 16949.
A TQM supports me to develop my company to excellence.
The structure of a QMS is the task of top management.
Mark the situations that pose a problem.
The customer complains about 3 parts in this week and the cause of the error is unclear.
Every Monday, the committee is higher than Tuesdays and Wednesdays.
Although a training concept on paint defects has reached every employee, the scrap in the paint shop is constantly poor.
**Every time when you don’t know the reason of a state or situation you can call this a problem.
What is a failure, what is a problem?
failure
• mismatch of your determined requirements
• unwanted status (e.g. product/process)
problem
• if the path to your solution is not obvious
• unwanted status reoccurs
**A failure is not necessarily a problem. It becomes a problem if your activity to fix the failure is not successful and you don’t know the root cause of the failure.
What is an abnormality at a Key Performance Indicator (KPI) in your Shopfloor Management?
if a KPI bounces significantly
if a value changes without influencing the process
Which of the following statements about the 8D report are correct?
- The 8D method is suitable for complicated problem solving
- If I have a simple problem, I solve it and monitor whether the problem reappears. If there are repeated errors, I go into a new process with an 8-step problem solving sheet
- For an 8D process I need a team of several experts
Which of the following statements are correct for problem solving?
Good shopfloor management is an early indicator of problems.
On a control chart I can see the course of my value as well as the customer requirements for the value and the intervention limits in the factory.
Assign the tools necessary for simple problems to the need for advanced tools.
- 5W, Concern (problem identification), cause, countermeasure
- Analysis with the Q Tools
- A3 Problem Solving Sheet
- Six Sigma Tools
Assign the tools necessary for simple problems to the need for advanced tools.
- 5W, Concern (problem identification), cause, countermeasure
- Analysis with the Q Tools
- A3 Problem Solving Sheet
- Six Sigma Tools
Try to start with your problem-solving process as easy as possible. Don’t shoot with a bazooka on birds.
Which statements are true when it comes to data?
Improvements can be shown based on a your data collection.
The data collection is done at the beginning on a project.
What are the differences between Lean and Six Sigma?
Lean
Sustainability needs to be improved
High implementation speed
Six Sigma
Implementation after lengthy analysis
High sustainability
If you collect an infinite amount of data, how will the distribution look like?
like a bell curve
like a normal distribution curve
If you achieve a world-class process according to Six Sigma understanding, what’s the defect rate then?
3.4
What are the different type of data?
Binary
• yes/no
• ok/not ok
Quantity
• 13 errors
• 2 Junior Consultants
Nominal
• never/sometimes/most of the time/always
Ordinal
• 1/2/3/4/5
• A/B/C/D/E/F
Continuous
• Volume
What do you have to do, when the spread of your process is too wide?
understand the variation of the process in order to reduce it (smaller sigma)
What do you have to do, when the location of your process is not centered?
understand the parameters for the location and then move it to the center
What are consequences of digital Shopfloor Management?
- Increase of data quality due to minor failure risk
- Increase of data availability from processes
- Real-time data allows quick response
- Less effort for capturing, processing & visualization of data
What are types of latency in the problem-solving process?
- data latency
- analysis latency
- decision latency
- implementation latency
Assign the process steps to the correct phases of the SFM.
Preparation Process
• Recording of data
• Visualization of data
• processing of data
SFM Meeting
• Check deviations in the fields of SQDCM & add. KPIs
• Define counter measures
• Check progress on problem-solving; escalate if support is required
Problem-Solving
• Following problem-solving according to PDCA / A3 Problem- solving process
• Derive & implement preventive measures based on prognoses
What are the criteria for the evaluation of the SFM phases?
Preparation Process
• Analogue: manually on paper based on observations & discussions
• Automatic: data will be recorded, processed & visualized automatically
• Digital: manual execution based on digital data
SFM Meeting
• Visualization: answer to what happened is given
• Transparency: answer to why it happened is given
• Prognoses: answer to the question what will happen is given
• Autonomy: system derives & executes measures
Problem-solving
• on premises analogue: Problem-solving process is documented and tracked on paper-base
• Integrated digital system (MES): access for every stakeholder – link to affected KPI’s is given
• anywhere digital: documentation & tracking in document-based systems
What are requirements for eSFM implementation?
data sourcing content updating vertical integration maintaining connectivity to front end
Which aspects are to be identified in your stakeholder analysis?
the stakeholder’s attitude to the project
the stakeholder’s expectations of the project
the stakeholder’s influence on the project
Where do you find answers about these questions for your TOS Project? Current condition? Why now? Project target? How to reach the target?
described in the project charter
To be even more precise, the question about how to reach the target is usually only partially mentioned in the project charter, later on it is visible in the implementation TIP.
Which statements regarding change management are true?
Stable conditions are needed to create profit
If I see a reason to change, I am more willing to leave the current stable condition
Put the different stages of the change curve in the correct order.
- Blame others
- Blame yourself
- Uncertainty/Confusion
- Acceptance/ Rationalization
- Problem solving
- Moving on
Which aspects have an influence on the first impression?
appearance
body language
voice
