Lecture 1: introduction to Lean Sigma, Six Sigma

Question 1

Definition of Lean

Answer 1

an approach to emphasises the smooth flow of items synchronised to demand to identify waste

Question 2

Definition of Six Sigma

Answer 2

A disciplined methodology of improving every product, process, and transaction

Question 3

What happens when you combine and apply lean and Six Sigma in the company level

Answer 3

It will result in companies improvement. All these improvement approaches share overlapping sets of elements

Question 4

What is Six Sigma about

Answer 4

improvement of products/ services in terms of quality it leads to reduction of defects, defective products/ variations

Question 5

What does lean do?

Answer 5

It helps company to be efficient and reduces cost

Question 6

Why is lean six sigma effective and efficient?

Answer 6

It is effective because it reduces variation and reduces defects
It is efficient because it reduces waste, and value added-steps

Question 7

What are the five key principles of lean?

Answer 7

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

Question 8

What is Six Sigma

Answer 8

It is an organizational philosophy, a methodology, a standard deviation of population, and a process capability metric

Question 9

What is the goal of Six Sigma

Answer 9

To reduce variation related to the variation within process output (Y) caused by input or process variables. To reduce variation towards customer target and specifications, To reduce variation by eliminating waste

Question 10

What are the key benefits when applying Six Sigma

Answer 10

high customer satisfaction, high employee satisfaction, and increase in shareholders value

Question 11

How can customer satisfaction be achieved

Answer 11

• Conformance to specifications (crosby)
• Value
• Fitness for use (juran)
• support
• Psychological impressions

Question 12

What are the steps to monitor progress: DMAIC? (5)

Answer 12

1. Define-the opportunity from both business and customer perspectives
2. Measure -Understand the process and its performance
3. analyze- search for the key factors that have the biggest impact on process performance
4. improve -Develop improvement solutions for the critical X’s
   5 control- Implement the solution and control plan

Question 13

What is the Six Sigma methodology

Answer 13

Define, Measure, Analyze, Improve and control.

It is used to improve existing processes

Question 14

Define stage DMAIC

Answer 14

describe the problem we are working and the CTQ organize the team -> get to know the problem

Question 15

Measure stage DMAIC

Answer 15

define the defect. Choose Y, describe process, collect data with capable measurement system, establish baseline process capability and establish improvement goals (to know how big the problem is)

Question 16

Analyze stage DMAIC

Answer 16

determine which process inputs most influence the key process outputs (identify the root causes, understanding the gap)

Question 17

Improve stage DMAIC

Answer 17

identify routes to improving performance& confirm changes will achieve the project goals (find solution to address the root causes in the identify phase)

Question 18

Control stage DMAIC

Answer 18

implement the solution and establish an ongoing mechanism to “lock-in” the improvement and to share them elsewhere (implement the solutions and measure the success by the use of control tools

Question 19

Different lean six sigma certifications

Answer 19

IASSC certification

ASQ

Question 20

Lean Six Sigma roles (5)

Answer 20

Yellow belts
Green belts
Black belts
Project sponsor
Deployment manager

Question 21

Lean Six sigma roles; yellow belts

Answer 21

awareness level

participation in project part-time in the function

Question 22

Lean Six sigma roles; green belts

Answer 22

certified level of competency
lead projects part-time in their function
responsible for majority of projects and six sigma benefits
understands internal and external supply chains improvement needs

Question 23

Lean Six sigma roles; black belts

Answer 23

Certified position/ demonstrated performers
Lead projects full time in their function
Dedicated to lead projects & train and coach green belts
Can define and improve supply chains using lean six sigma techniques

Question 24

Lean Six sigma roles; project sponsor

Answer 24

identify opportunities, initiate & define projects
Creates an environment for GB/ BB to complete projects
Decision-maker during tollgate review

Question 25

Lean Six sigma roles; deployment manager

Answer 25

lead project prioritization
manage black belts
track financial returns
track certification of black belts and green belts
create environment of knowledge sharing

Question 26

Different ways to express process quality

Answer 26

DPMO
Yield %
CpK
σ, level

Question 27

DPMO

Answer 27

defect per million opportunities

Question 28

Yield

Answer 28

number of good products relative to the number of produced products. Chance of producing a unit with no defects/ errors

Question 29

CpK

Answer 29

process capability relative to products specifications

Question 30

σ, level

Answer 30

statistical measure of a process ability to consumer requirements

Question 31

What does Six Sigma imply?

Answer 31

it implies process thinking
X (input cause) -> Y (output effect)
In other words Y= f (X’s). also know as transfer function

Question 32

Just-in-time (JIT)

Answer 32

A philosophy of manufacturing based on planned elimination of all waste and on continous improvement of productivity

Question 33

Customer satisfaction can be achieved by

Answer 33

• Conformance to specification
• Value
• Fitness for use
• Support
• Psychological impressions