Lean_Six_Sigma_100_Flashcards v3
What is the primary purpose of the Define Phase?
To identify the problem, define the project scope, and establish the goals of the improvement effort.
What tool is used to map out the high-level process flow in the Define Phase?
SIPOC (Suppliers, Inputs, Process, Outputs, Customers).
What does a Project Charter include?
Problem statement, project scope, objectives, timeline, and team roles.
What is the purpose of the Measure Phase?
To quantify the current performance and collect data on the process.
What are the key components of a data collection plan?
Data to be collected, data sources, sampling methods, and operational definitions.
What is a process capability analysis used for?
To determine how well a process meets customer specifications.
What is the goal of the Analyze Phase?
To identify root causes of process defects or inefficiencies.
Name three tools commonly used in the Analyze Phase.
Fishbone Diagram (Ishikawa), 5 Whys, Pareto Analysis.
What is the purpose of a regression analysis in the Analyze Phase?
To identify relationships between variables and their impact on the outcome.
What is the main focus of the Improve Phase?
To implement and test solutions that address the root causes of defects.
What is a Design of Experiments (DOE)?
A statistical method used to determine the effect of multiple variables on an outcome.
What is a pilot study, and why is it conducted?
A small-scale implementation of a solution to test its effectiveness before full deployment.
What is the purpose of the Control Phase?
To sustain the improvements and ensure that the process remains stable over time.
Name two tools used in the Control Phase.
Control Charts and Standard Operating Procedures (SOPs).
What is a Control Plan?
A document outlining the monitoring and response strategies to maintain process performance.
What does DPMO stand for, and how is it calculated?
Defects Per Million Opportunities; DPMO = (Defects / Opportunities × Units) × 1,000,000.
What is the difference between Type I and Type II errors in hypothesis testing?
Type I error is rejecting a true null hypothesis (false positive), and Type II error is failing to reject a false null hypothesis (false negative).
What is the significance of a p-value in hypothesis testing?
It indicates the probability of observing the test results under the null hypothesis. A p-value less than 0.05 typically suggests statistical significance.
What is the purpose of Value Stream Mapping (VSM)?
To visualize the flow of materials and information through a process to identify waste.
What are the 8 types of waste in Lean?
Transportation, Inventory, Motion, Waiting, Overproduction, Overprocessing, Defects, and Skills (TIMWOODS).
What is a Kaizen event?
A focused, short-term project to improve a process quickly.
What does DMAIC stand for?
Define, Measure, Analyze, Improve, Control.
How does DMAIC differ from DMADV?
DMAIC focuses on improving existing processes, while DMADV (Define, Measure, Analyze, Design, Verify) is for designing new processes.
What are Critical to Quality (CTQ) factors?
Attributes most important to the customer, derived from customer requirements.
What is a stakeholder analysis used for?
To identify and manage individuals or groups affected by the project.
What is a RACI matrix?
A tool that outlines who is Responsible, Accountable, Consulted, and Informed for specific tasks.
What is VOC, and why is it important?
Voice of the Customer; it captures customer needs and expectations to guide improvement efforts.
What is the purpose of a baseline measurement?
To establish the starting point for process performance before improvements.
What is the Gage R&R study used for?
To assess the precision and consistency of measurement systems.
What is the difference between continuous and discrete data?
Continuous data can take any value within a range, while discrete data is countable and finite.
What is a sampling plan?
A strategy for collecting data from a subset of the population to represent the whole.
What is hypothesis testing?
A statistical method to determine if there is enough evidence to reject a null hypothesis.
What is root cause analysis (RCA)?
A method to identify the primary cause of a problem.
What does FMEA stand for, and what is its purpose?
Failure Modes and Effects Analysis; it identifies and prioritizes potential failures in a process.
What is a Pareto chart, and how is it used?
A bar chart that ranks causes or defects by frequency to focus on the most significant issues.
What is brainstorming, and how is it applied?
A technique for generating creative ideas to solve problems.
What are the 5S principles?
Sort, Set in order, Shine, Standardize, Sustain; they organize and improve the workplace.
What is a control-impact matrix?
A tool to prioritize improvement actions based on their control and impact.
What is mistake-proofing (Poka-Yoke)?
Designing processes to prevent errors or detect them immediately.
What is SPC, and why is it used?
Statistical Process Control; it monitors and controls process variation.
What are leading and lagging indicators?
Leading indicators predict future performance, while lagging indicators measure past results.
How does standardization help in the Control Phase?
It ensures consistency and repeatability of improved processes.
What is the role of training in sustaining improvements?
To equip employees with the knowledge and skills to maintain process improvements.
What is takt time?
The rate at which a product must be completed to meet customer demand.
What is a bottleneck, and why is it important?
The slowest part of a process that limits overall throughput.
What is the purpose of a value-added analysis?
To identify and reduce non-value-added activities in a process.
What is a kanban system?
A visual system to manage workflow and inventory in a just-in-time environment.
What is the role of benchmarking in Lean Six Sigma?
To compare processes against industry standards or best practices for improvement.
What is the purpose of an affinity diagram?
To organize ideas and identify patterns for problem-solving.
What is the difference between correlation and causation?
Correlation is a relationship between variables; causation implies one variable causes the other.
What is a histogram?
A graphical representation of the distribution of data.
What is the Central Limit Theorem?
It states that the sampling distribution of the mean approaches normality as sample size increases.
What is the purpose of an ANOVA test?
To compare means across multiple groups to determine if there are significant differences.
What is the difference between common cause and special cause variation?
Common cause variation is inherent to the process, while special cause variation is due to specific, identifiable factors.
What is the purpose of a control chart?
To monitor process stability and detect unusual variation.
What is the standard deviation, and why is it important?
A measure of the spread of data around the mean, indicating process variability.
What does Cp measure in process capability?
The potential capability of a process to meet specifications, assuming it is centered.
What is Cpk, and how does it differ from Cp?
Cpk measures the actual capability of a process, accounting for whether it is centered within specifications.
What is a null hypothesis in hypothesis testing?
A statement that there is no effect or difference, tested for possible rejection.
What is a Type I error in hypothesis testing?
Incorrectly rejecting a true null hypothesis (false positive).
What is a Type II error in hypothesis testing?
Failing to reject a false null hypothesis (false negative).
What is a scatter plot used for?
To visualize relationships between two variables.
What is a confidence interval?
A range of values within which the true population parameter is expected to fall with a specified confidence level.
What is a box plot, and what does it represent?
A graphical representation of data showing the median, quartiles, and outliers.
What is the purpose of a process map?
To visualize the steps, inputs, and outputs of a process.
What is Little’s Law?
It relates throughput, work-in-process, and cycle time in a stable process: WIP = Throughput × Cycle Time.
What is a spaghetti diagram?
A visual representation of the physical flow of materials or people in a process.
What is the role of a Lean Six Sigma Green Belt?
To lead improvement projects and support Black Belts in larger initiatives.
What are the three main types of control charts?
X-bar/R charts, P-charts, and C-charts.
What is a Kaizen event?
A focused, short-term initiative to make rapid process improvements.
What is takt time, and how is it calculated?
The maximum time per unit allowed to meet customer demand; calculated as available time / customer demand.
What is the purpose of an Ishikawa (fishbone) diagram?
To identify and organize potential causes of a problem.
What is the 80/20 rule (Pareto Principle)?
80% of effects come from 20% of causes.
What is the difference between Lean and Six Sigma?
Lean focuses on eliminating waste, while Six Sigma focuses on reducing variation.
What is takt time?
The time it takes to produce one unit to meet customer demand.
What is the purpose of hypothesis testing in Lean Six Sigma?
To statistically determine if there is a significant difference between groups or changes.
What is a SIPOC diagram?
A high-level process map identifying Suppliers, Inputs, Process, Outputs, and Customers.
What is the purpose of a Value Stream Map?
To identify and eliminate waste in the process flow.
What is a Gantt chart?
A tool used for project scheduling and tracking progress over time.
What is a Monte Carlo simulation?
A statistical technique to model and analyze the impact of risk and uncertainty.
What is Kanban?
A visual scheduling system to optimize workflow and inventory management.
What is the purpose of a root cause analysis?
To systematically identify the underlying cause of a problem.
What are the 7 wastes identified in Lean?
Transportation, Inventory, Motion, Waiting, Overproduction, Overprocessing, and Defects (TIMWOOD).
What is the purpose of a histogram in Lean Six Sigma?
To visualize the distribution of data and identify patterns or outliers.
What is the purpose of a control plan in the Control phase?
To ensure the improvements are sustained by defining monitoring and response strategies.
What is a Project Charter?
A document that defines the objectives, scope, and participants of a project.
What is the DMAIC methodology?
A structured problem-solving approach: Define, Measure, Analyze, Improve, Control.
What is an operational definition?
A clear and measurable definition of a concept or variable.
What is process capability?
A measure of how well a process produces output within specification limits.
What is the purpose of benchmarking?
To compare your process or performance against best-in-class standards.
What is Voice of the Customer (VOC)?
Customer needs, wants, and expectations, collected to guide process improvements.
What is the purpose of a control chart?
To monitor process performance and identify variation over time.
What is the purpose of a fishbone diagram?
To identify potential causes of a problem in a structured manner.
What is a balanced scorecard?
A strategic planning tool that measures organizational performance in multiple areas.
What is standard work?
A documented and consistent approach to performing tasks or processes.
What is a SIPOC diagram?
A tool used to define and map the high-level view of a process, including Suppliers, Inputs, Process, Outputs, and Customers.
What is the purpose of regression analysis?
To identify relationships between independent variables and a dependent variable.
What is the purpose of a control plan?
To ensure process improvements are maintained by monitoring critical metrics and response plans.
What is an affinity diagram?
A tool to organize ideas into themes for better understanding and analysis.
