Six Sigma- Module 1 Flashcards
List the eight forms of waste. Hint: “DOWNTIME.”
- Defects
- Overproduction
- Waiting
- Non-utilized Talent
- Transportation
- Inventory
- Motion
- Extra Processing
What is a Prioritization Matrix?
It is typically an L-shaped matrix that makes pairwise comparisons of established criteria and options. The Prioritization Matrix is a rigorous method and requires skills to use effectively.
Define Brainstorming.
It is a method for generating a large number of creative ideas in a short period of time. Typically, a large list is created which may eventually be boiled down, or funneled down, to a smaller list of priority items later in the project.
List three situations where you would use Brainstorming.
- When a broad range of options are desired
- When creative ideas are desired
- When the participation of an entire team is desired
What are the six principles of SIX SIGMA?
- Find and eliminate causes of defects and errors
- Reduce cycle times
- Reduce costs of operations
- Improve productivity
- Strive for perfection by reducing variation
- Meet customer demands
What decade did Motorola’s Bill Smith, an Engineer, and Bob Galvin, CEO, seek a way to reduce defects and improve their operation process?
1980’s
What year did Motorola trademark the name “SIX SIGMA”?
1985
What were Carl Friedrich Gauss’s (German Mathematician) key contributions to SIX SIGMA?
- Normal curve metric as an error analysis tool for measurement
*Probability and hypothesis testing; a principle cornerstone of Six Sigma
What was Vilfredo Pareto’s (Italian Economist) key contribution to SIX SIGMA?
The Pareto Principle, which identifies the separation of the significant few (the 20%) from the trivial many (80%). This concept is a key component of six sigma improvement planning, where the goal is to identify the critical few (20%) causes that lead to the most significant quality improvement.
What were Philip Crosby’s ( American Businessman and Author ) key contributions to SIX SIGMA?
Popularized the concepts of “cost of poor quality” and the four absolutes of quality management:
- Quality comes from conformance
- Quality comes from prevention
- Quality standard of zero defects
- Measurement of Quality is the cost of non-conformance
What were Dr. W. Edwards Deming’s ( American engineer, statistician, and Professor ) key contributions to SIX SIGMA?
*Promoted the work of Walter Shewhart and brought Shewhart’s “Plan-Do-Check-Act” cycle into popularity (came to be called the “Deming Cycle”)
What was Dr. Armand V. Feigenbaum’s ( American Quality Control Expert and Businessman ) key contribution to SIX SIGMA?
Credited with the strategies for Total Quality Control, or TQC, which included concepts that higher quality leads to lower lower costs, quality is everyone’s responsibility, and management must be included in quality improvement.
What were Dr. Kaoru Ishikawa’s ( Japanese Engineering Professor at the University of Tokyo) key contributions to SIX SIGMA?
- Developed the Ishikawa Diagram, known today as the fishbone diagram or cause and effect diagram?
*Proposed company wide quality control, CWQC, which is a 2-5 year commitment from both employees and management dedicated to quality improvement.
*Originated “Quality Circles”, Which utilizes the Plan-Do-Check-Act (PDCA) cycle.
*Proposed a company’s quality problems could be solved through the use of seven basic tools:
1. Flow charts
2. Ishikawa Diagrams
3. Checklists
4. Pareto Charts
5. Histograms
6. Scatter Plots
7. Control Charts
What were Dr. Walter A. Shewhart’s ( American Physicist, Engineer, and Statistician ) key contributions to Six Sigma?
- Known as the Father of Statistical Process Control
- Introduced use of Control Charts
- Originated the Plan-Do-Check-Act (PDCA)
What were Dr. Joesph M. Juran’s (Romanian-born American Engineer and Management Consultant) key contributions to SIX SIGMA?
- Theorized that the 80/20 principle of Pareto could be applied to any organizational operation
- Proposed that management should be present in quality councils or “quality circles”
*His quality trilogy consisted of quality planning, quality control and quality improvement
What were Frederick Winslow Taylor’s (American Mechanical Engineer) key contributions to SIX SIGMA?
- Considered the first scholar of American business
- Introduced three core principles of project management and leadership: Benchmarking, Process Resign, and Work Out.
*Proponent of standardized process and measured performance
What is the difference between Six Sigma and Lean?
- Six sigma focuses on reducing defects and variation and is frequently described as effectiveness.
*Lean focuses on increasing value, decreasing waste, and streamlining the flow which is sometimes called efficiency.
How does Six Sigma define quality?
Minimum deviation from the appropriate target
What number does Six Sigma aim to reduce the risk of a defect?
3.4 defects per million opportunities
What percentage range of annual revenue do experts in Six Sigma say is lost to the cost of poor quality?
20 - 40 %
What are the four concepts of “the cost of poor quality”?
- Internal Failures
- External Failures
- Appraisal Costs
- Prevention Costs
List the ten items in “Internal Failures”.
- Accidents
- Workarounds
- Quick Fixes
- Scrap
- Rework
- Defects
- Mistakes
- Employee Turnover
- Equipment Downtime
- Sorting
List the six items in “External Failures”.
- Customer Complaints
- Penalties
- Liability suits
- Repair and warranty costs
- Time spent evaluating things that have gone wrong
- Time spent responding to an upset customer
Lists the five items in “Appraisal Costs” .
- Measuring, evaluating, auditing
- Audits
- Testing
- Inspections
- Equipment Calibration
List the 6 items in “Prevention Costs” .
- Planning, Training, and all efforts to prevent poor quality
- Error Proofing
- Capability Studies
- Procedure Writing
- Applicant Screening
- Education and Training
What is “Value Add Rule” number one?
It has to change the form or the function
What is “Value Add Rule” number two?
The customer must be willing to pay for it
What is “Value Add Rule” number three?
You need to get it right the first time
What does the Japanese term “Muda” mean?
Anything that is wasteful and doesn’t add value
How does Six Sigma describe waste?
Any activity that consumes resources but creates no value
How does Six Sigma describe defects?
Efforts caused by rework, scrap, or misinformation. It can also include:
*Missing or wrong supplies
*Flaws
*Customer Complaints
*Warranty Returns
*Liability Exposure
How does Six Sigma describe process improvement?
The objective is to improve processes in terms of both effectiveness and efficiency
What is Descriptive Statistics?
Descriptive statistics makes use of numerical summaries of data and effective graphical displays
What is Inferential Statistics?
Inferential statistics uses various statistical methods to make inferences about a population based on information obtained from a sample
What are the two types of data that are often encountered in Six Sigma?
- Attribute Data
- Variable Data
What is attribute data?
It is either a yes or no, a go or no-go, a pass for a fail. It can be characterized or categorized in classifications, and we can then count how many show up in each one of the classes. Also referred to as discrete data.
What is variable data?
Data that is measurable and can be quantified
What does “D.M.A.I.C” stand for?
Define
Measure
Analyze
Improve
Control
Describe the “Define” stage of DMAIC system.
The project is initiated, and a specific problem is defined. The project’s goals and scope and the stakeholder are identified. Then a clear project charter is developed based on the problems that affect the stakeholder.
Describe the “Measure” stage of DMAIC system.
Measurement systems are developed and evaluated. Current process performance is measured, and key performance indicators are determined. Data is collected, and its quality of it is checked for accuracy. Summary statistics such as distribution are used to gauge how the process is behaving, and finally, the level of defects and variation is determined.
