Lecture 8 - Control Flashcards
Continue "Improve" Introduction to "Control" • Changing the mind-sets • Standardisation & Visual Management • SPC • Closing a project
Poka-Yoke is also known as…
Mistake Proofing
The purpose of Poka-Yoke is to…
Assure the required quality of products while minimising the waste in the product
What are the objectives of Poka-Yoke?
- To identify critical to quality features of a product
* To develop and implement an error proofing device in the process
Are inspection and testing valid methods for improving quality? Why?
No, we must think LEAN.
If the defect is PREVENTED from occurring, it is no longer a problem.
Does the Poka-Yoke (mistake proofing) technique prevent abnormalities from becoming defects?
Yes it does!
Name three Poka-Yoke sources of mistakes for a Service Provider
- Activities
- Behaviors
- Tangibles
Name three Poka-Yoke sources of mistakes for a Customer
- Preparation
- Encounter
- Resolution
The essential concept of the Theory of Constraints (TOC) is…
that every organisation must have at least one constraint.
True / False?
The Theory of Constraints (TOC) states every organisation should have at least THREE constraints.
False.
TOC states that every organisation must have at least ONE constraint.
True / False?
Theory of Constraints (TOC) is a Six-Step Process
False.
TOC is a five-step process
Theory of Constraints:
Describe step one,
“Identify the System Constraint”
The part of a system that constitutes the weakest link, either a physical or intangible constraint
Theory of Constraints:
Describe step two,
“Decide how to exploit the constraint”
Obtain as much capability as possible from a constraining component, but do not carry out expensive changes or upgrades
Theory of Constraints:
Describe step three,
“Subordinate Everything Else”
- Adjust non-constraint components of system to maximise the constraint.
- Evaluate the system to determine if the constraint has shifted
- (Return to step one of TOC if constraint is eliminated)
Theory of Constraints: If a constraint has been eliminated by step three, we should a) End the TOC process b) Further elevate the constraint c) Try to exploit the constraint further d) Repeat the TOC process
d) Repeat the TOC process
The TOC should not end, and should continue iteratively.
If the constraint has been eliminated, there is no constraint to further elevate or exploit!
Theory of Constraints:
Describe step four,
“Elevate the Constraint”
Take necessary actions to eliminate the constraint
We only consider this step if the previous steps (“Decide How to Exploit the Constraint” and “Subordinate Everything Else”) have been unsuccessful.
Theory of Constraints:
Describe step five:
Return to step one, “Identify the System Constraint”
But beware of “Inertia”!
In TOC Throughput represents…
All the money coming into an organisation.
Increasing throughput will lead to increased profit
In TOC Inventory represents…
All the money tied up inside an organisation.
Decreasing inventory will lead to increased profit
In TOC Operating Expense represents…
The money leaving the organisation.
Decreasing operating expenses will increase profits
True / False?
The Inventory of an organisation will increase when they use the Theory of Constraints (TOC)
False.
The inventory will decrease as the organisation only has assets which it immediately requires
True / False?
(TOC) Throughput, Inventory and Operating Expense are interdependent on one another.
True.
All three of these measures are interdependent.
To improve an organisation using TOC, you aim to:
_______ Throughput.
_______ Inventory.
_______ Operating Expense.
To improve an organisation using TOC, you aim to:
Maximise Throughput.
Minimise Inventory.
Minimise Operating Expense.
DMAIC: Control
The main aim of the control phase is…
to ensure that the process improvements stay
Through “Control” we want to make sure that everyone performs the process using…
methods which are proven using data to give desired results
In order for “Control” to happen, we need to ensure that the ______ process becomes the ______ process
In order for “Control” to happen, we need to ensure that the “new” process becomes the “standard” process
What are the four parts to “Control”?
- Changing Mind-sets
- Documenting and Standardising the Improvement
- Monitoring the process
- Implementing a Control Strategy
What are the four requirements for “Changing-Mindsets” in the control phase?
- Purpose
- Skills
- Reinforcement
- Role Models
What does “Document and Standardise” involve?
- Involving stakeholders
- Agreeing on the need
- Understanding the Scope and Impact
- Improvements are proven / tested
- Improvement is sustained
To achieve effective Standardisation we can use ______ and __________.
To achieve effective Standardisation we can use
“Visuals” at the workplace and Peer training.
Give three examples of “Visual” standardisation at the workplace
- Pictures
- Flowcharts
- Training people
During “Sustain and Monitor” we ____ and ____.
During “Sustain and Monitor” we track the lead indicators and run charts and trends.
Give four advantages of Run Charts
- Easy to draft
- Easy to analyse & interpret
- Does not require much technical skill
- Straightforward representation of data
Give three disadvantages of Run Charts
- Don’t have statistical control limits
- Not capable of showing you if the process is stable and in control
- Need to be aware of the context / situation in which data has been collected
Statistical Process Control (SPC) is a methodology based on…
statistical thinking, which uses basic graphical and statistical tools to analyse, control and reduce variability within a process
True / False?
Statistical Process Control (SPC) is equally applicable to manufacturing and non-manufacturing environments
True!
SPC is equally applicable to manufacturing and non-manufacturing environments
Statistical Process Control (SPC) is about achieving quality through the control of processes, i.e…
during production rather than relying on inspection after items have been made
In SPC, what does “Statistical” refer to?
- Collecting Data
- Forming Patterns
- Predicting Future Performance
In SPC, what does “Process refer to?
6MS • Methods • Manpower • Measurement • Environment - Thats not a M! >:( • Machine • Materials
In SPC, what does “Control” refer to?
- Comparison with the target
- Eliminating any special causes
- Adjusting (but only if necessary!)
Give three reasons why should we use Statistical Process Control (SPC)
- SPC allows us to make decisions based on an understanding of the real levels of variation in the process
- It allows us to recognise when our processes are out of control
- It lets us separate the capability of the process to meet customer requirements
True / False?
Process Capability is the same as Process Control
False
Process Capability is NOT the same as Process Control
Control charts indicate when a process is _____ or exhibiting _______
Control charts indicate when a process is “out of control” or exhibiting “Special Cause Variation”.
Control charts allow workers and supervision to maintain…
improved process performance from LSS Projects
SPC (Statistical Process Control) Charts incorporate…
upper and lower Control Limits
Control Charts can be applied…
with all processes
Caution be taken when using SPC for processes with a ___________.
Caution be taken when using SPC for processes with a non-normal distribution.
True / False?
Control limits describe the process variability and are unrelated to customer specifics
True!
Control limits is concerned with VOP instead of VOC
What are the three steps for building a control chart?
- Data Collection
- Control using the data collected to find out if the process is stable
- Improvements
“Control Plan Strategy”
The intent of an effective control plan strategy is to…?
(5 reasons)
- Operate processes consistently on target with minimum variation
- Minimise Process Tampering (i.e. over-adjustment)
- Assure that the process improvements that have been identified and implemented become institutionalized
- Provide for adequate training in all procedures
- Include required maintenance schedules
What type of charts can we use to graphically demonstrate improvement?
- Histograms,
- Control Charts,
- Pareto Charts
What does PDCA stand for?
- Plan - plan carefully what you want to try out
- Do - try it out
- Check - what happened?
- Act - implement the learning (or abandon that idea and • try something else)
True / False
The PDCA is a learning cycle which can only be applied to a LSS project management environment
False
The PDCA is a learning process which can be applied to ANY process management environment
What are the four steps for Documenting and Communicating results?
- What were your results?
- Did they meet the goal?
- What else did you learn about the process?
- Describe how the results can be maintained
What are the benefits for hosting a project closure?
- Thanks the core team
- Thanks the extended team and stakeholders
- Recognition for you and the team
Also Underlines that the project is now over and ownership has transferred to the process owner
There are two sources of mistakes which Poka Yoke can address in the service environment.
____ and ____.
There are two sources of mistakes which Poka Yoke can address in the service environment.
Service Provider and Customer.
