Lean Six Sigma Flashcards
Lean definition
Elimination of all non-value-added activities. this could be unnecessary steps or actives, rework, waiting time, ect. Visible problems.
The elegant solution?
A maximum effect is achieved with the simplest and smallest effort.
What is Six Sigma (hint: DMAIC)
Define Measure Analyze Improve Control
Six Sigma (DMAIC step 1) Define
process mapping, expectations including financials, specific problems. Always keep customer in mind, customer should come first in six sigma!
Six Sigma (DMAIC step 2) Measure
"If you can't measure something, you can't understand it". First define what data you need? Utilization rate? Yield? (scrap rate, rework rate, ect.) Process time? Use value stream mapping to measure
Six Sigma (DMAIC step 3) Analyze
Focuses on why? Why are you having this problem. (this is where the statistical part of six sigma comes in, but I don’t think ACBikinis needs this).
How does the process work and how SHOULD it work?
Six Sigma (DMAIC step 3) Analyze The 5 whys technique?
Ask why 5 times to find the root cause of the problem.
Many times the problem is employee training.
Six Sigma (DMAIC step 4) Improve
The heart of six sigma. Implement a change to fix the problem.
Step 1: Brainstorming
Step 2: Communication (this is KEY!!!)
Step 3: Implement!
The solution many times involves lean applications (lean operations are designed to streamline processes)
Six Sigma (DMAIC step 5) Control
The most important phase of DMAIC. When you make the improvement permanent. This could be checklist, QC things, monthly reviews, ect. It’s CRUCIAL that the new process is documented and monitored.
Mistake prevention and mistake proofing (when a mistake happens it is not passed on to the next person), like when you repeat the order to a customer.
Lean approach
- Determine the value
- Identify the value stream
- Make value flow without interruptions
- Allow the customer to pull value (only produce what is needed to supply customer demands).
- Perfection
What is a process map?
A map you make to use lean that will help you identify any steps not needed. Like waste, cycle time, and inventory. notice that lean does not include any statistics (That is six sigma). Hopefully this map will help you improve customer service, better use of resources, reduced inventories, and a higher quality product.
Five Ss of Lean
Sort Set in order Shine (clean!) Standardize (consistent) Sustain
Just in time concept of Lean
Raw materials are delivered just as needed to meet customer demands. Reduces inventory and adds flexibility. It is customer demand that drives ordering. Created by Henry Ford. Controlled by Kanban System (kanban means “sign” or “signal”). A card signals the workers when work/inventory is needed to be done. The work is triggered by customer orders. The card will be very specific to customer needs. Total inventory is reduces and throughput is increased. JIT needs an effective delivery system. This would make it impossible to use with companies in Asia because it takes so long to get products and there is a lot of variability in the amount of time.
Quality at the source
Important for ACBikinis and almost what we do. Any employee can stop the manufacturing to ensure the highest quality to the consumer. Poka-yoka. Cuts down on quality checks, could be improved and stop the quality checkpoints.
Kaizen definition
Gradual and orderly continuous improvement. All business actives! (and personal). Not trying to make the process perfect, just a little better every day.
- Have procedures and systems set.
- Teach employees this is also their responsibility
- Training - classes for employees to help them become a little better on a personal level too.
