Lean brainscape for test Flashcards
What are the 6Ss of Six Sigma?
Sort; Set in order; Shine; Standardise; Safe; Sustain
What does Kaizen mean?
Methodical process analysis; Include people in the process; continuous improvement
What are the 3 components of Lean to embed CI in an organisation?
Management Systems & Control; Excellent Processes; High performance teams
What is unnevenness of operation called? 3Ms
Mura
What is a PDCA Cycle also known as?
Deming cycle
What 5 things should the ideal process be?
Right; On time; First time; Every time; At minimum cost
What is Gemba?
The workplace/ the shop floor
What is box 6 of the A3 nine box process?
Future state
What mapping techniques should be used for Process level?
Functional deployment mapping; four fields
What are Kipling’s 6 questions for problem solving and creating a problem statement?
What; Why; When; Where; How; Who
What does SCAMPER stand for?
Substitute; Combine; Add; Modify; put to other Purposes; Eliminate; Rearrange/Reverse
What is a “Deming Cycle” also known as?
PDCA cycle
What are the 5 key features of Kaizen?
Continuous; incremental; participative; low cost; uses staff knowledge
What is box 4 of the A3 nine box process?
Problems/Issues & Challenges
What is cycle time?
Average time taken by any work centre to process one item
How to calculate the efficiency of the process (or valued added ratio)?
Value added time divided by total time
How should customers be segmented for VoC?
by similar need for products and services
What are Delighters?
Excitement requirements - unexpected features that impress customers
Who was Six Sigma developed by?
Motorola
What is failure demand?
Demand resulting from the provider not doing what the customer expects, or breaks promises
What are the four stages of problem solving methodology?
Problem investigation; Grasp the situation; Cause investigation; Root Cause identification; Solution!
What is the Kano model?
Helps understand customer needs - Dissatisfiers; Satisfiers; Delighters
What is box 8 of the A3 nine box process?
Benefits
What is the probability of a good making it through a multi-step process called?
The rolled throughput yield
What is the yield?
The Probability of a good product
What is going to the workplace called?
Gemba
What is Muri?
Overburdening
What did Sakich Toyada develop in 1902
A loom that stops automatically on defect
When was “The Machine that changed the world” released?
1990
What are the 3 main methods of improvement?
Breakthrough improvement; Continuous improvement;’A mis of the two!
What is box 3 of the A3 nine box process?
SMART improvement targets
When was “Lean Thinking” released?
1996
What is box 2 of the A3 nine box process?
Current state data
What are “Sangen Shugi”?
The three actualities - Place; Part; Situation - Genchi; Genbutsu; Genjitsu
Similarities between Lean and Six Sigma
Continuous improvement; customer focused; improve quality; structured approach to identifying and eliminating root causes
What does SIPOC stand for?
Suppliers; Inputs; Processes; Outputs; Customers
What are the 3Ms? (the focus of lean)
Mura; Muda, Muri
What is box 7 of the A3 nine box process?
Actions
Who wrote “Lean Thinking”?
Womack and Jones
What is the most important waste according to Ohno?
Over-production
What are the focuses of Lean?
Shortening throughput time of the value steam; eliminating waste; Direct shop-floor observation; improvement with the organisation
What is the Hawthorne effect?
Change in behaviour when being observed
What is Muda?
Waste
What are the four stages of Kaizen method?
Analyse; Trials; Make changes; Implement
What are the 5 steps for gathering and analysing the Voice of the Customer?
Identify; Segment; Listen to VoC; Translate VoC to CCR; Prioritise; Defince process indicators
Benefits of an A3 report?
Logical thinking; decision making (1 page); Standardised approach; Forces all issues to be addressed; Focuses on problem solving; Eliminates waste; Forces questions
What is box 1 of the A3 nine box process?
Reason for improvement
What is “Genchi Genbutsu”?
Management by fact or go show me - to see and do oneself is to truly understand
What mapping techniques should be used for Enterprise level?
SIPOC; Enterprise Modelling (Porter)
What is Poka-yoke?
Mistake proofing
What are Satisfiers?
Standard and expected characteristics that are spoken and expected by customers
What is planned cycle time?
The target time - geneally set at about 85% of Takt time
Who was the pioneer of Kaizen?
Masaaki Imai - Gemba Kaizen
Who invented the “Stand in a circle” method
Taiichi Ohno
What are the 5 principle prompts of the future state map?
Value; Value Stream; Flow; Pull; Perfection
What are the focuses of Six Sigma?
Reducing variation; improving the process to add customer value; data and statistics based; improvement of the organisation
What is the point of Pareto charts?
Focus attention to the problems causing most waste - therefore promoting efficient countermeasures
What chart could be used for showing movement of people/goods most effectively?
Spaghetti chart
What are the problem solving techniques?
Three actualities (Sangen Shugi); Stand in a circle; Gemba; Problem recognition; Root causes; Kipling; 5 Whys; Cause and effect/Fishbone; Pareto charts;
What are the steps for translating VoC to CCR?
Voice of the customer (what they say); Key customer issue (what they want); Critical to customer requirement (how they want it)
What is the definition of a Customer?
Any person or organisation that receives a product or service (output) from the work activities (process)
What are the normal bones on the fishbone?
5M and 1P - measurement, machinery; mother nature; material; method; people
What mapping techniques should be used for System level?
SIPOC; Value Stream Mapping
Who wrote “The Machine that changed the world”?
Womack, Jones and Roos
When was Six Sigma invented?
1985
What is box 9 of the A3 nine box process?
Insights
What are the 3 types of Kaizen?
Gemba Kaizen; Hoshin Kaizen; Kaikaku
What are Dissatisfiers?
Expected features that are often unspoken but create disappointment if not present
What are the three categories of waste walks?
Proactive/CI/Kaizen; Post-improvement control/audit; Identify Value and Failure Demand
What are the 3 levels of mapping hierarchy?
Enterprise; System; Process
What is Waste called? 3Ms
Muda
What are the 3 elements of the ideal state?
Diagram; Description; Principles
What is overburdening called?
Muri
What is the probability of a good product called?
The yield
How do we improve?
Understand where you are now; Detemine where you need to get to; Work out how to get there!
What is Mura?
Unnevenness of operation
Lean focuses on…
Right things, right place, right time, right quantity… whilst minimising waste, being flexible and able to adapt
What is a method for driving problem focus and results?
Pareto charts
What are the four things to consider when implementing Lean?
Pressure to change; Vision; Capacity to change; Actionable first steps
What is a value stream?
All actions required to bring a product or service from concept to launch and from order to delivery
What are the five principles of Lean?
Value; Value Stream; Flow; Pull; Perfection
What is waste?
Activity that does not add value as defined by the customer
Who invented the automatic stopping loom?
Sakichi Toyoda (1902)
What are the 3 challenges for performance measurement?
Quantification; balance; unintended consequences
How to identify the customers for VoC?
Use the SIPOC
What is box 5 of the A3 nine box process?
Way ahead
What is value demand?
Demand for a service, created by the customer when they need something from a provider
What is the Takt time?
Total available time MINUS losses DIVIDED BY Customer Demand - it’s the rate of production required to fulfil demand
What are the sources of customer information for VoC (step 3)?
Internal and External data; Listening post; Research methods
