Sec 9 Lean & Quality Systems Flashcards
What are the 4 objectives of productivity and quality systems?
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
What are 5 expectations for a satisfied customer?
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
What 6 requirements do customers have of their suppliers?
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
What is Quality Function Deployment (QFD)?
Methodology designed to ensure all major requirements of customer are identified and met or exceeded
What is House of Quality
Structured process relating customer-defined attributes to the products technical features that are needed to meet and support these attributes
What are 6 rooms in the House of Quality
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
What are 5 parts of Lean
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
Lean– 8 categories of waste
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
What is takt time?
Rate of customer demand.
define Total Productive Maintenance (TPM)
Preventative maintenance plus ongoing efforts to adapt/modify/refine equipment to increase flexibility, reduce material handling, and promote continuous flow
define Process Improvement
Activities designed to identify and eliminate causes of poor quality, process variation, and non-value-added activities
define Continuous Improvement
Never-ending effort to expose and eliminate root causes of problems.
Kaizens
Kaizens
Small-step improvement as opposed to big-step improvements
define Value Stream Mapping
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
Heijunka
production leveling to match the rate of end-product sales.
Product and mix are distributed evenly over time
Five Ss
sort simplify scrub standardize sustain
Hoshin Planning
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
What are 2 categories of quality related costs?
1) Cost of Failure – internal and/or external
2) Cost of Controlling Quality – prevention and appraisal costs
What are the 7 basic quality tools
1) Flowchart
2) Cause & Effect
3) Control Charts
4) Check Sheet
5) Histogram
6) Pareto
7) Scatter Diagram
Define Flowchart
Used to visualize the tasks/elements needed and the steps/sequence of those tasks
define Cause & Effect diagram
aka Fishbone diagram
illustrates main causes and sub-causes leading to an effect
6 “bones” – material, machine, people, method, environment, measurement
define control charts
tools used to track process variation
define Statistical Process Control (SPC)
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
define Process Capability
a measure of process spread in relation to the upper and lower specification limits
Statistical Process Control vs Product Inspection
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
define Check Sheet
Simple data-recording devises designed to summarize a tally count of event occurences
define Histogram
Graph of contiguous vertical bars representing a frequency distribution.
Frequency is on the y axis
define Pareto
graphical tool for ranking causes from most significant to least significant
bars placed in descending order from highest to lowest
define Scatter Diagram
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
Six Sigma
Set of concepts and practices that focus on reducing variation in processes and therefore reduced defects and improves quality
What is Six Sigma target for # of defects?
3.4 defects per million opportunities which equals 99.999 percent good product.
Six Sigma causes of variation?
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
what is Six Sigma DMAIC?
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
