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Lean 6 Sigma > Lecture 7 - Introduction to Improve > Flashcards

Lecture 7 - Introduction to Improve Flashcards

1
Q

Discuss how improvements are made in company (x3)

A
  • Generating Solutions
  • Use Improvement tools
  • Understand different solution types for selection
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2
Q

Name 3 Improvement tools

A
  • 5S
  • SMED
  • Poka Yoke (Lean)
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3
Q

Improve - simple steps to take (x4)

A
  • Creative thinking - idea generation.
  • Prioritise for selection.
  • Pilot Development - refine & finalise.
  • Implementation programme - change/manage
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4
Q

Name 4 Generation tools

A
  • Brainstorming
  • Participatory groups
  • Focus groups
  • 5 -3- 5
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5
Q

Name 3 Selection tools

A
  • Six thinking hats
  • Evaluation grid
  • Cost benefit analysis
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6
Q

Name 2 Development tools

A
  • Prototype…….. Pilot

* Testing/Stress testing

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7
Q

Name 2 Implementation tools

A
  • Change management

* Project management

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8
Q

Discuss Brain-storming (x4)

A
  • Based on good understanding of group dynamic
  • Don’t follow the rules (criticise while thinking)
  • Less effective if over-used
  • Equal contribution
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9
Q

Discuss P-I-T Method (x5)

A

5 People - 3 Ideas each - every 5 minutes

  • generate group output
  • Independent
  • Time constrained
  • Drawing/sketching/annotated output
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10
Q

P-I-T Method steps (x3)

A
  • Everyone sketch 3 ideas
  • pass your sheet to next person
  • Then adapt, combine or new idea

Repeat till needed

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11
Q

5S Purpose and Objective

A
  • create consistent outputs and maintain safe and clean working environment where people enjoy working
  • support smooth flow of materials and information
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12
Q

What are the 5’s ?

A

Sort - (Clear Out)
Set - Order/Stabilise (Configure) layout /current / labelled / check list / ease of use
Shine - (Clean & Check)
Standardise - (Conformity)
Sustain - (custom & Practice) Audits / progress reports / update activities /

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13
Q

Why 5s?

A
  • Create the best environment to reduce lead times and waste

* More efficient responsiveness

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14
Q

What is SMED

A

• SMED is the Single Minute Exchange of Die system

Single Minute means Single Digit minute up to 9.99 minutes

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15
Q

SMED Purpose

A
  • Reduced in-process stock,
  • Shorter lead time
  • Just In Time supply of product
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16
Q

SMED Objectives

A
  • Reduce the set up time BETWEEN stages of a process (ie handover of info/ material)
  • Improve safety and productivity
17
Q

SMED Steps

A
  • One – Identify Pilot Area
  • Two – Identify elements
  • Three – Separate external elements
  • Four – Convert internals into externals
  • Five - Streamline remaining elements
18
Q

SMED Step (Pilot area) (x5)

A
  • Duration
  • Variation
  • Opportunities
  • Familiarity
  • Constraint
19
Q

SMED Step (elements) (x4)

A
  • Elements - parts to process
  • Sticky Notes - process mapping
  • Man & Machine - interactions
  • Observe - video taping & observers
20
Q

SMED Step (external) (x4)

A
  • Retrieval - required things
  • Inspection
  • Cleaning - stand by tasks
  • Quality - checking
21
Q

SMED Step (Convert) (x4)

A
  • Advance Preparation - pre work before processing
  • Jigs - sort alignment and adjustments
  • Modularize - replace component during maintenance (one on the run and one spare)
  • Modify - guarding for cleaning
22
Q

SMED Step (Streamline) (x7)

A
  • Release - quick release mechanisms
  • Adjustment - minimise needed adjustments (have saved settings)
  • Motion - minimise
  • Waiting - minimise
  • Standardising - fewer options available
  • Operations - parallel operations but needs thought having >1 person in area

• Mechanise - ?

23
Q

Improvements types (3)

A
  • quick win - human improvements
  • medium effort - human tasks
  • long term - technical improvements equipment/settings/design
24
Q

Define Poka-Yoke (4)

A

• assure required quality of products with a minimum waste.

  • identify critical to quality features
  • develop and implement error proofing device

Basically it requires a ‘physical’ test that the components needs to pass through.
ie) square shape in circle hole.

25
Q

Define Theory of Constraints (TOC) (1)

A

• constraint is any factor that limits the organisation from getting more of whatever it strives for

26
Q

TOC Process - Five Step

A
  • One – Identify the System Constraint
  • Two – Decide How to Exploit the Constraint
  • Three – Try altering Everything Else
  • Four – Eliminate the Constraint
  • Five - Return to Step One,… But beware of “Inertia
27
Q

Increasing profit using TOC

A

• Maximise Throughput while Minimising Inventory and Operating Expense

28
Q

2 types of Engineering

A

• Hard Engineering
Higher cost, semi rigid,
A higher level of skill is required

• SoftEngineering
Low cost, quick to install for trials.
Adjustments, even small ones can be easily carried out

29
Q

De Bono’s Six Thinking Hats

A
  • Questions (asks for everything that is needed)
  • Thinking (thinking process)
  • Bad points (devils advocate)
  • Emotions (human factors)
  • Creativity (adaptions)
  • Good points judgement (optimist)
30
Q

De Bono’s Thinking Grid

A

Option 1 – As a group go through each of the questions
•Option 2 – As an individual go through each of the questions
•Option 3 – As a group, assign hat roles, and have a discussion on each of the questions in your selected hat mode

Lean 6 Sigma (9 decks)

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