Lecture 1 Flashcards by Fleur van der Velden

What is lean management?

Improving the efficiency of a process -> decreasing costs

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What is six sigma management?

Making sure quality is enhanced -> improvement of products/services quality -> reduction of defects & variations

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What are the two drivers of lean six sigma?

Quality + speed

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What means ‘effective’ in lean six sigma?

Reduce variation

- Reduce defects

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What means ‘efficient’ in lean six sigma?

Reduce waste

- Lean Value-Added Steps

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What is a defect?

When one aspect of the product/service does not meet the requirements

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Finish the sentence:

“When lean and six sigma are combined in the company level, this will result in…

Companies improvement

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What is the Hawthorne experiment?

Showed how worker productivity could be improved by worker participation

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When did the Hawthorne experiment take place?

1920’s

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What is the W. Edwards Deming method?

Method for statistical analysis and control of quality to Japanese engineers and executives (origin of TQM)

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When was W. Edwards Deming’s method developed?

In the 1950’s

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What was the role of Kaoru Ishikawa?

The reduction of the philosophy contributed to Japan’s ascendancy as a quality leader

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When did Kaoru Ishikawa rise?

In 1968

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What are the five key principles of lean according to Womack?

Define value add and non-value add
Map the value stream
Establish process flow
Shift from push to pull systems
Strive for perfection / zero defects

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What is six sigma (3)?

An organizational philosophy/ BPI approach (variation and business impact)
A methodology
A standard deviation of a population

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What are the goals of Six Sigma?

Reduce variation related to the variation with process output caused by the input or process variables (x’s)
Reduce variation towards customer target & specifications
Reduce variation by eliminating waste

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Customer satisfaction can be achieved by (5):

Conformance to specifications
Value
Fitness for Use
Support
Psychological impressions

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Customer satisfaction in higher education (5):

Conformance to specifications
Value
Fitness for Use
Support
Psychological impressions

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How is progress monitored (5) (DMAIC)?

Define
Measure
Analyze
Improve
Control

Explain the ‘Define’ stage of how progress is monitored

Define -> define the opportunity from both business and customer perspectives.

Explain the ‘Measure’ stage of how progress is monitored

Measure -> Understand the process and its performance

Explain the ‘Analyze’ stage of how progress is monitored

Analyze -> Search for key factors (critical X’s) that have the biggest impact on process performance and determine the root causes

Explain the ‘Improve’ stage of how progress is monitored

Improve -> Develop improvement solutions for the critical X’s

Explain the ‘Control’ stage of how progress is monitored

Control -> Implement the solution and control plan

What are critical enablers of how progress is monitored?

1. Project selection 2. Project sponsorship 3. Tollgate reviews

What are the stages of the 'low hanging fruit matrix'

1. Aim at low hanging fruit 2. Feasible projects (don't try to solve world hunger) 3. Business results with limited investments 4. Data available 5. High probability of sucess

Explain the first stage of the Six Sigma methodology (DMAIC):

Define: Describe the problem we are working on and the CTQ. Organize the team

Explain the second stage of the Six Sigma methodology (DMAIC):

Measure: Define the defect. Choose Y. Describe the process. Collect data with a capable measurement system. Establish baseline process capability. Establish improvement goals.

Explain the third stage of the Six Sigma methodology (DMAIC):

Analyze: determine which process inputs (Xs) most influence the key process outputs (Y)

Explain the fourth stage of the Six Sigma methodology (DMAIC):

Improve: Identify routes to improving performance & confirm changes will achieve the project goals

Explain the fifth stage of the Six Sigma methodology (DMAIC):

Control: Implement the solution and establish ongoing mechanisms to 'lock in' the improvements and to share them elsewhere.

What are the roles of of the yellow six sigma belt?

- Awareness level | - Participation in project part-time in the function

What are the roles of of the green six sigma belt?

- Certified level of competency - Lead project part-time in their function - Responsible for the majority of projects and Six Sigma benefits - Understands internal and external supply chains improvements needs

What are the roles of of the black six sigma belt?

- Certified position / demonstrated performers - Lead projects full time in their function - Dedicated to leading projects & train and coaching green belts - Can define and improve supply chains using Lean Six Sigma techniques

What are the lean six sigma roles? (2)

1. Project sponsor | 2. Deployment manager

Explain the Lean Six Sigma role as 'project sponsor'

- identify opportunities, initiate & define projects - Creates an environment for GB/BB to complete the project (remove barriers, provide resources, etc) - Decision-maker during tollgate review

Explain the Lean Six Sigma role as 'Deployment manager'

- Lead project prioritization - Manage black belts - Track financial returns - Track certification of black belts and green belts - Create an environment of knowledge sharing

What are the types of charts/diagrams that fall under the 'define' stage (DMAIC)?

- Pareto chart - Process Flow Chart - Value-added Flow Chart - Project priority Calculator - Failure Mode & Effects Analysis (FMEA)

What are the types of charts/diagrams that fall under the 'Measure' stage (DMAIC)?

- Measurement System Analysis - Trend Chart - Statistical Process Control (SPC) - Six Sigma Conversion Table

What are the types of charts/diagrams that fall under the 'Analyze' stage (DMAIC)?

- Fishbone diagram - Histogram - 5-Why analysis - Regression analysis - Design of experiments - Statistics Handbook

What are the types of charts/diagrams that fall under the 'Improve' stage (DMAIC)?

- Brainstorming - System diagrams - Error proofing - Corrective action matrix - CHECK process

What are the types of charts/diagrams that fall under the 'Control' stage (DMAIC)?

- Control plan - SPC - CHECK process - FMEA - 5S

What is lean?

An approach that emphasizes the smooth flow of items synchronized to demand to identify waste

What is six sigma?

A disciplined methodology of improving every product, process and transaction

What are different ways to express process quality?

DPMO: Defects per million opportunities Yield %: Number of good products relative to the number of produced products CpK: Process capabilities relative to the product specifications δ: Statistical measure of a process ability to customer requirements

Where do you have to apply LSS?

1. Manufacturing activities 2. Transactional and administrative activities 3. Management activities

What kind of thinking does six sigma imply?

Process thinking | X input cause ----> Y output effect