Measure Phase

Question 1

key components of the measure phase

Answer 1

Identify Inputs, data collection, measurement system analysis MSA, process capability/stability, & outputs

Question 2

techniques that can be used for inputs

Answer 2

x-y matrix, 5whys, fishbone diagram, FMEA

Question 3

Process mapping tools

Answer 3

SIPOC, flowchart, flow chart, deployment flow chart

Question 4

VSM Value Stream Map

Answer 4

putting icons together in a process flow then adding data evolving about how long it takes to do things (use when figuring out TIME)

Question 5

Spaghetti diagram

Answer 5

step to step in a physical layout, REGARDING DISTANCE

Question 6

TRUE/FALSE The fewer the step the less confusion and things that can go wrong.

Answer 6

TRUE

Question 7

top-down flow chart (commonly used for process mapping)

Answer 7

selectively expanding from highest level (5-9 high level activities) keep expanding until problem is reached

Question 8

Activity Diagram/Process Flowchart

Answer 8

captures decision points, rework looks, complexity

Question 9

Deployment Flowchart is used for___

Answer 9

large complex processes, multiple departments, handoffs are easily illustrated

Question 10

What process is important for deployment

Answer 10

sequence and time of processes

Question 11

VSM created to identify all the activities involved in ______ the product or _____ from start to finish

Answer 11

producing

service

Question 12

What is included in the value stream for VSM?

Answer 12

supplies, operations, and end customer

Question 13

Data regarding what times with inventories are useful for the Value Stream Map?

Answer 13

Lead & processing times

Question 14

Define Uptime

Answer 14

% of time the process can operate if product is available (max uptime is typically 95% for most machines due to variablity and delays)

Question 15

Define Setup Time

Answer 15

time to change from one type of work to anther

Question 16

Define Batch size

Answer 16

quantity of product worked on and moved at one time

Question 17

Define Rework Rate

Answer 17

% of total product that does not meet the customer requirement and must be worked again

Question 18

Define Scrap Rate

Answer 18

% of total product that does not meet the customers requirement and must be discarded

Question 19

Define Defect Rate

Answer 19

% of total product that does not meet the customers requirement (includes scrap & rework)

Question 20

Define Processing Time P/T

Answer 20

time the product is actually within a process being worked EX: time it takes to do something

Question 21

Define Cycle Time C/T = P/T divided by # of people working in process step

Answer 21

how often a part or product is actually completed by a process. the processing/production rate of a process or process step. Takes into account parallel processing processing and staffing

Question 22

Define Lead Times L/T

Answer 22

elapsed time it takes a product to move through the defined Value Stream start to finish. This includes all processing time & waiting and other Non Value Added time

Question 23

Define Number of People

Answer 23

of people required to operate the process

Question 24

Define Process Capacity

Answer 24

Available work time X Uptime % (divided by) Highest cycle time in process

Question 25

Define Littles Law

Answer 25

used to estimate lead time for a process or wait time for a process step

Question 26

Determine Lead Time

Answer 26

WIP(work in process/inventory/backlog) divided by Output Rate

Question 27

Example of finding Lead Time: Output rate 30 orders/hr

Backlog: 100 orders

Answer 27

100 orders X 60min/200 minutes

Question 28

(3) Steps to find the Process Capacity

Answer 28

1. Find step with highest cycle time CT (Process time/#of people or orders
2. Calculate Available Time
   (consider the hrs per shift)
3. Calculate Process Capability

Question 29

Value Add Flow Analysis activities (3)

Answer 29

Customer Value Added, Business Value Added, Non-value Added (used to identify steps in a process for which the customer is really willing to pay for and what they wont)

Question 30

Objective of value add flow analysis is to ____ the hidden costs, ____ unnecessary process complexity and related errors, _____ the process cycle time, _____ capacity by better utilizing resources

Answer 30

Eliminate the hidden costs, reduce unnecessary process complexity and related errors, reduce the process cycle time, increase capacity by better utilizing resources

Question 31

True/False

Value Added is what the customers are willing to pay for

Answer 31

TRUE

Question 32

True/False Business Value Added is the required financial activities

Answer 32

TRUE

Question 33

Non-Value Added NVA steps are…

Answer 33

Does not add value, defects, errors, omissions, preparation/setup, inspection, 8 sources of wastes

Question 34

What chart can you use to summarize and display the value added/business value,& non value added

Answer 34

Pareto chart

Question 35

The mission for Value Add Flow is to improve the process by

Answer 35

eliminating the NVA, Reduce BVA, and Optimize the CVA

Question 36

Spaghetti Diagrams is a graphical tool used to illustrate ____ and ____

Answer 36

space & distance

Question 37

X-Y Matrix, the X are the inputs such as

Answer 37

controllable inputs, procedural inputs, noise (uncontrollable factors)

Question 38

The X INPUTS can be used in other methods such as…..

Answer 38

Fishbone diagram, Process mapping, Data analysis

Question 39

Fishbone technique includes labelling material, machine, method, ______, ______, & _____.

Answer 39

manpower, mother nature, measurements

Question 40

FMEA Stands for?

Answer 40

Failure Mode & Effect Analysis

Question 41

What is FMEA?

Answer 41

a structured or qualitative risk analysis of a system, design, or process in a product or service