Sec 9 Lean & Quality Systems

Question 1

What are the 4 objectives of productivity and quality systems?

Answer 1

1) Ensure quality of product definition
2) Ensure quality in the design process
3) Ensure quality during manufacturing packaging processes
4) Ensure quality from the perspective of the customer

Question 2

What are 5 expectations for a satisfied customer?

Answer 2

1) Product performance (include reliability, durability, and maintainability
2) Features - secondary characteristics like mpg
3) Conformance to established standards/specs
4) Warranty
5) Sustainability- provides present benefits without compromising needs of future generations

Question 3

What 6 requirements do customers have of their suppliers?

Answer 3

1) High quality
2) High flexibility to change volume, specs, delivery date, etc
3) High service level
4) Short lead time
5) Low variability in meeting targets
6) Low cost

Question 4

What is Quality Function Deployment (QFD)?

Answer 4

Methodology designed to ensure all major requirements of customer are identified and met or exceeded

Question 5

What is House of Quality

Answer 5

Structured process relating customer-defined attributes to the products technical features that are needed to meet and support these attributes

Question 6

What are 6 rooms in the House of Quality

Answer 6

1) Identify customer requirements
2) Identify supporting technical design requirements
3) Compare customer requirements to the design requirements and assign relationship ratings
4) Assign importance to the customer requirements
5) Evaluate competitors
6) Identify technical features to be deployed in the final product design

Question 7

What are 5 parts of Lean

Answer 7

1) Any activity that doesn’t add value from customer’s perspective is waste
2) JIT – Processes should be pulled by the customer and flow at rate of customer demand
3) Jidoka – Employees are empowered to stop the production line if a defect occurs
4) Standardization of work and reduce variation by leveling volume and mix of orders over time
5) Instills a culture of continuous improvement with everyone is involved

Question 8

Lean– 8 categories of waste

Answer 8

1) Process
2) Movement (of products)
3) Methods (motion of operators
4) Product defects
5) Waiting time - work queue
6) Overproduction
7) Excess inventory
8) Unused people skills

Question 9

What is takt time?

Answer 9

Rate of customer demand.

Question 10

define Total Productive Maintenance (TPM)

Answer 10

Preventative maintenance plus ongoing efforts to adapt/modify/refine equipment to increase flexibility, reduce material handling, and promote continuous flow

Question 11

define Process Improvement

Answer 11

Activities designed to identify and eliminate causes of poor quality, process variation, and non-value-added activities

Question 12

define Continuous Improvement

Answer 12

Never-ending effort to expose and eliminate root causes of problems.

Kaizens

Question 13

Kaizens

Answer 13

Small-step improvement as opposed to big-step improvements

Question 14

define Value Stream Mapping

Answer 14

a graphical representation plotting the path from raw material to finished good.

Include production data like takt time and cycle time

Shows both value added and non-value-added activities

Question 15

Heijunka

Answer 15

production leveling to match the rate of end-product sales.

Product and mix are distributed evenly over time

Question 16

Five Ss

Answer 16

sort
simplify
scrub
standardize
sustain

Question 17

Hoshin Planning

Answer 17

lean version of strategic planning

Top management develop up to 4 vision statements that are then used to develop specific corporate goals for the next five years. Then audit periodically

Question 18

What are 2 categories of quality related costs?

Answer 18

1) Cost of Failure – internal and/or external

2) Cost of Controlling Quality – prevention and appraisal costs

Question 19

What are the 7 basic quality tools

Answer 19

1) Flowchart
2) Cause & Effect
3) Control Charts
4) Check Sheet
5) Histogram
6) Pareto
7) Scatter Diagram

Question 20

Define Flowchart

Answer 20

Used to visualize the tasks/elements needed and the steps/sequence of those tasks

Question 21

define Cause & Effect diagram

Answer 21

aka Fishbone diagram

illustrates main causes and sub-causes leading to an effect

6 “bones” – material, machine, people, method, environment, measurement

Question 22

define control charts

Answer 22

tools used to track process variation

Question 23

define Statistical Process Control (SPC)

Answer 23

applies statistical techniques to monitor and adjust an operation.

Select processes capable of production required quality products

Monitor processes to ensure they continue to produce required level of quality

Question 24

define Process Capability

Answer 24

a measure of process spread in relation to the upper and lower specification limits

Question 25

Statistical Process Control vs Product Inspection

Answer 25

Statistical Process Control tries to control processes to prevent defects before they happen

Product inspection finds defects after they occur and is wasteful because often customer isn’t willing to pay for it. Does not necessarily find the root cause

Question 26

define Check Sheet

Answer 26

Simple data-recording devises designed to summarize a tally count of event occurences

Question 27

define Histogram

Answer 27

Graph of contiguous vertical bars representing a frequency distribution.

Frequency is on the y axis

Question 28

define Pareto

Answer 28

graphical tool for ranking causes from most significant to least significant

bars placed in descending order from highest to lowest

Question 29

define Scatter Diagram

Answer 29

used to analyze relationship between two variables — one on x axis and one on y axis

If no relationship is evident then points on the graph will appear widely scattered

Question 30

Six Sigma

Answer 30

Set of concepts and practices that focus on reducing variation in processes and therefore reduced defects and improves quality

Question 31

What is Six Sigma target for # of defects?

Answer 31

3.4 defects per million opportunities which equals 99.999 percent good product.

Question 32

Six Sigma causes of variation?

Answer 32

Special Causes – isolated and assignable to a particular source.

Common Causes – are inherent in a process due to poor process design or poor working conditions

Question 33

what is Six Sigma DMAIC?

Answer 33

Define - Identify customer’s problems and processes. Quantify improvement goals along with potential benefits to the company in order to determine overall costs and benefits of fixing the problem.

Measure – all the data necessary to understand the process

Analyze - Determine cause-and-effect relationships that produce variation or contribute to the problem

Improve – develop and implement solutions

Control – Ensure the gains are maintained