LEAN Flashcards
What is DMAIC in Lean ?
Define Measure, Analyze, Improve Control
Which tools are included in DEFINE ?
Problem definition Project charter SIPOC
Tools for MEASURE
- Data collection 2. Spaghetti diagrams 3. Swimlane diagrams 4. Value stream mapping 5. Process flow mapping
Tools for ANALYZE
- Root cause analysis 2. 5 WHY’s 3. Pareto analysis 4. Capacity and bottleneck identification
Tools for IMPROVE stage in LEAN (7 in total)
- 5S 2. Layout 3. Standard work 4. Poka Yoke 5. TPM 6. Takt time & pull 7. Kaizen
Tools for CONTROL stage in LEAN
- Visual control 2. Audit & control plan 3. ROI
What are requirements for Lean Project Goals ?
It must be: S - specific M - measurable A - attainable R - relevant T - time bound
SIPOC steps
Hierarchy of Process Discovery
What are the benefits of SIPOC ?
What is Value added thing ?
Something, what is customer willing to pay for
What ar three rules of waste ?
What are 8 types of waste ?
D - defect (rework and errors (documents and tools) )
O- overproduction (doing unncessary work not requested)
W- waiting (waiting for the next process)
N - non engaging employee (under utilized employees)
T - transportation (transport of documents & equipment which is not necessary)
I - inventory (obsolete, excess inventory, shortage of parts)
M - motion (unnecessary movements
E - extra processing (unnecessary processing, process of getting approvals..)
8 types of waste
What are three additional types of waste (except main 8 ) ?
- Inappropriate systems
- Wasted material
- Wasted Utility Resources
What is Lead Time ?
How to measure Degree of Leanness ?
What is three point estimate ?
Typical lean improvements
What should included in all Lean metrics ?
- Strategic company goal
- Project goal (waste minimization)
- Customer requirements
Why to collect data for lean ?
What is Spaghetti Diagram ?
Spaghetti Diagram is graphical tool, used to depict the physical flow of work or material in a process.
What is th most common applicatio of Spaghetti Diagram ?
Make movement of people more efficient,
What is Swimlane Diagram ?
Cross-function mapping tool that visualizes the process flow by responsibility
What is RACI charting ?
A systematic technique for clarifying roles and responsibilities in a work activity within the process.
R - responsible (do the job. execute)
A- accountable (make the decision.take ultimate ownership)
C - consult (communicate in advanc)
I - inform (need to know, but don’t have an impact on decision)
What are the benefits of using RACI charts ?
What are roles of Swimlane diagrams and RACI ?
Process flow map faciliate a greater understanding of a process by identifying …..
- Bottlenecks
- Redundancies
- Key inputs and outputs
- Key decision points for criteria
- Roles and responsibilities
Process flow map describe …..
- Major activities/tasks
- Process workflow
- Value added and non-value added steps
- Process boundaries
- Input variables (X’s)
- Output variables (Y’s)
- Where data is (or should be) collected
What is relation between VSM and Swimlane Diagrams regarding to Process Flow Maps ?
In a summary, what Process Flow Maps do ?
Describe Schlumberger Investigation Process
What is SCAT ?
Schlumberger’s Systematic Cause Analysis Technique
Lack of Control > Root Cause > Immediate Cause > Incident > Loss
Describe 5 Whys process
There are two main types of action items: short term and long term. What are the main characteristics of action items ?
What is the criteria to find out, if action item resolves root cause ?
What is Fishbone diagram ?
Cause and Effect Diagram
What are main parts of Fishbone diagram ?
What is Pareto Principle ?
Describe Pareto Analysis
Pareto analysis may use both:
- Frequncy of occurence
- Total cost
Most frequently ocurring may not be the most costly one
Focus first on low project costs wth high impact
What is capacity ?
How to Improve System Capacity ?
- Identify th system constraint
- Develop a plan to mitigae the system constraint
- Align every part of the system to support the constraints even if this reduces the efficiency of non-constrained resources
- Elevate the system constraints. If output is still inadequate, acquire more of this resource
- If the constraint has been broken go back to number 1
What is Nominal time ?
Nominal time = Total time - Planned downtime (lunch, break to refuel, etc..)
What is effective time ?
Effective time = Total Time - total downtime (planned, unplanned)
What is bottleneck ?
What 5S stands for ?
Sort
Set in order
Shin
Standardize
Sustain
What are requirements for Base Lean Layout ?
- Single direction flow of truck traffic to avoid congestion and increase safey
- Single direction flow on the shop floor from receiving to shipping
- Equipment should maintain one orientation throughout all movements on the shop floor
- Using tool carts reduces demand and lost time waiting for cranes or forklift
- Wet and dry areas should be separated to minimize overspray, humidity, and contamination
What factors drive the effectiveness of the workplace ?
Critical design guidelines for layout (1 to 5)
- Single flow of truck traffic
- Single direction flow for equipment processing
- Maintain one orientation (tools)
- Motorized tool carts (reduce wait time for cranes, forklifts)
- Separate wet and dry areas (humidity)
- Third party inspection not to interrupt the process
What are critical design guidelines for layout (6 to 10)
- Third party inspection not to interrupt the process
- Schedule work based on “pull” system
- Work area of the next process should be adjacent to the previous process
- Mechanical workstation incorporates benches, shadow boards and carts that integrate with the bench
- Portable electrical benches
Describe 7 steps in layout design process
List advantages of Lean Layout in a summary
What is takt time ?
What is Volume Leveling in Tak Time ?
It is to reduce the variation in demand on any process
What is Mix Leveling in Takt Time ?
To reduce the variation in the mix of activities to be performed by establishing a set schedule
What choices exist for Volume Leveling Choices ?
- Level volume by buffering (kanban)
- Pull additional resources when required
- Reduce the root cause for variation
What are Standardized Work Implementatin Process ?
- Determine product/service family groupings and takt time
- Observe and map the process
- Identify Standard Work Process
- Develop Stanard Work Package
- Implement Standard Work Practices
- Monitor Work Performance KPI
What is mistake proofing ?
Using process and/or design features to prevent errors or their negative impact. (Poka Yoke in Japanese)
What are benefits of Mistake Proofing ?
- Inexpensive
- Very effective
- Based on simplicity and ingenuity
- Ma
Describe Levels of Mistake Proofing
- Level 1 : Defect / mistake cannot occur
- Level 2: Defect can occur but will not be passed on
- Level 3: Defect / Mistake is possible but there is a gauge (or device) to detect the problem and provide a reaction
What kind of errors/defects are addressed by Poka Yoke (Mistake Proofing) ?
Defects/errors caused by human mistakes
In summary, what is Push-Pull Kanban ?
- Push is traditional batch and queue
- Push maximizes individual process efficiencies
- Pull is consumption based processing
- Pull maximizes value stream effectiveness
- Flow where you can, pull where you must and never push
What Kanban means in Japanese ?
Signal
What are benefits of Visually Controlling activities with Kanban systems ?
- Allows the flow f work to be controlled
- Standardizes spare parts inventory (kanban)
- Extremely flexible when demand changes
- Highlights capacity and personnel requirements
- Reduces waste
What are rules of Kanban and Pull systems ?
- Maintain equipment inventory to meet customer requirements (no extra)
- Order spares only when the previous spare was taken and only as much as was taken
- Maintain equipment to make sure you have equal or slightly greater than needed to meet customer requirements (no extra)
- Use kanban as a fine-tuning device. Do not start too early or too late. Reduce the amount of kanbans over time
- Stabilize and rationalize the process to fit with your ogranization’s changing demand
What is Kanban in Lean ?
- It is a signal of process consumption
- It is a flexible, visual form of controlling work to be done or ready to support average operational needs
- Prevents overproduction
- Prioritizes the task
- Equipment control is easier
Describe process of taking decision to have Kaizen Event ?
Describe 4 phases of Kaizen Event
- Planning and preparation
- Implementation (the Event)
- Presentation and Celebration
- Follow-up and dissemination
What is Kaizen ?
Kai (to take apart) + Zen (to make good) = Kaizen (continuous improvement)
The kaizen concept focuses on each process or operation to add value and eliminate waste
What is most importan phase of Kaizen Event ?
- Follow up and dissemination
What is Kaizen Event ?
A team activity that consist of the use of Lean methods to rapidly eliminate waste in a chosen area. Usually lasts 4-5 days.
Consist of 4 phases
What is Visual Management Improvement Cycle ?
What is the benefit of Effective Visual Controls ?
Anyone can walk into a workplace and visually understand the current situation
In summary, what Visual Controls provide ?
What are the benefits of having Audit and Control Plans in place ?
- Control plans ensure that the process consistently meets customer requirements
- They should provide predictive activities, so adjustments can be made before processes are out of control
- They prevent the slippage of improvement progress
What is ROI ?
ROI (return on investmen) is a performance measure used to evaluate the efficiency of a single investment or compare the efficiency of a number of investments
What are benefits of LEAN ?
- Reduced CAPEX
- Increased efficiency
- Lower costs and improve SQ
- Improved Interfaces (between different departments)
What are two main types of projects in LEAN ?
- With impact on customer service
- With impact on reducing costs
What two main type of savings can be gained by LEAN projects ?
- Hard savings - can be measured directly
- Soft savings
What topics are covered in Lean Level 2 modules 1-5 ?
- DMAIC & LEAN
- Problem definition/Project Scope
- SIPOC
- Value & Waste
- Lean Metrics
What topics are covered in Lean Level 2 modules 6-10 ?
- Data Collection
- Spaghetti Diagram
- Swimlane / RACI
- VSM map
- Process Flow Maps
What topics are covered in Lean Level 2 modules 11-15 ?
- Root Cause Analysis
- Cause and Effect Diagram
- Pareto Diagram
- Capacity and bottleneck
- 5S
What topics are covered in Lean Level 2 modules 16-20 ?
- Lean Layout
- Takt Time
- Standardized Work
- Mistake Proofing
- Pull and Kanban
What topics are covered in Lean Level 2 modules 21-24 ?
- Kaizen
- Visual Control and Management
- Audit and Control Plan
- Benefits Capture and Project Value
What are characteristics of value added process ?
- It is what customer is willing to pay for 2. Something is changed during the process 3. Done right first time
How to develop a good problem stating?
Problem stating (PS) : describe current situation. Use metrics to define impact. Be specific without including causes or solutions. Answer below open questions: 1. What is the problem? 2. Why is the problem? 3. Where is the problem? 4. How is and/or big the problem? 5. When is it the problem? 6. Who is it problem for?
