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Pataky Six Sigma > Terms Exam 2 > Flashcards

Terms Exam 2 Flashcards

1
Q

______ ________ is a data driven problem solving methodology.

A

Six sigma

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2
Q

What is one hallmark of six sigma maturity?

A

Unwavering reliance on data

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3
Q

What must you do to get a concentrated stream out of the bottom of a funnel?

A

You must fill the top abundantly

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4
Q

The __________ phase pinpointed the location or source of problems as precisely as possible and established a baseline capability level.

A

Measure

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5
Q

The _________ determines and prioritizes root causes.

A

Analyze

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6
Q

Name 6 tools used for ideas

A 
Brainstorming
Nominal group technique
Five whys
Affinity diagram
Multi voting
Pairwise comparison
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7
Q

Name 6 tools used for process mapping and analysis

A 
SIPOC map
As is value stream maps
Relationship matrix
Ishikawa (cause and effect) diagrams
Cause and effects matrix
FMEA
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8
Q

Name 5 tools used for data collection

A 
Attribute (discrete) and variable (continuous) data
Single characteristics 
Paired characteristics (scatter diagrams)
Time dependent characteristics (run charts)
Observational studies
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9
Q

Raw facts

A

Data

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10
Q

Form - facts structure relation

A

Information

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11
Q

Pattern or trend

A

Knowledge

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12
Q

__________ ____________ analyze the variation in the observed critical output (Y) and identify which variables (X) are the most likely causes of the variation.

A

Observational studies

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13
Q

___________ control input variables (X) to see the effect on the output (Y)

A

Experiments

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14
Q

Some experiments are unrealistic or _________

A

Unethical

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15
Q

In analyzing differences in box and whisker plots _______ __________ implies the input variable (x) has an effect on the output (y)

A

Significant difference

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16
Q

What type of data analysis tool can you use for continuous input (x) and continuous output (y)?

A

Scatter plot

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17
Q

What type of data analysis tool can be used for discrete input and continuous output or continuous input and discreet output?

A

Stratified frequency plots

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18
Q

What type of data analysis tool can be used for discrete input (x) and discrete output (y)?

A

Table of results

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19
Q

T/F. Correlation equals causation

A

False

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20
Q

What are the five objectives to perform process analysis?

A
  1. Improve understanding of process flow
  2. Reduce cost
  3. Identify bottle necks and cycle time problems
  4. Identify value add activities
  5. Identify waste
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21
Q

Name 6 tools for perform process analysis

A 
SIPOC
Value Stream Mapping
Transportation and Spaghetti Diagrams
Value added flow analysis
Swim lane flow charts
Bottleneck analysis - theory of constraints
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22
Q

Munro defines a root cause as what?

A

A factor that caused a nonconformance and should be permanently eliminated through process improvement.

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23
Q

_________ root causes lead directly to the non conformance

A

Direct

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24
Q

___________ root causes are a chain of causes and effects that lead to the nonconformance.

A

Indirect

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25
Q

Name two new tools we have to determine and prioritize root causes

A

Interrelationship diagram

Multi vari studies

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26
Q

The purpose of a ________ _________ is to allow a team to systematically identify, analyze and classify the cause and effect relationships that exist among all critical issues so that key drivers and outcomes can become the heart of an effective solution

A

Interrelationship diagram

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27
Q

A ________ __________

  • encourages team members to think in multiple directions rather than linearly
  • explores the cause and effect relationship among all issues including the most controversial.
  • allows key issues to emerge naturally rather than allowing the issues to be forced by a dominant team member
  • systematically surfaces the basic assumptions and reasons for disagreement among team members
  • allows a team to identify root causes even when credible data does not exist
A

Interrelationship diagram

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28
Q

Name the 7 steps in the process for an interrelationship diagram

A
  1. Agree on problem statement or research question
  2. Document each critical input (x) on a post it note
  3. Assign a unique Id (letter or number) to each post it note
  4. Arrange post it notes in a large circle on a white board or flip chart
  5. Look for cause/influence relationships among all ideas and draw relationship arrows
  6. Tally the number of incoming and outgoing arrows
  7. Identify visually the key drivers (root causes) and key outcomes
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29
Q

___________ ____________ studies allow you to listen to the voice of the process and identify which inputs (x) are exerting an influence on the output (y)

A

Multi vari (multiple variable)

30
Q

Name three major categories of causes (x) of output (y) variation

A

Positional
Cyclical
Temporal

31
Q

__________ variation is defined as the magnitude of variation coming from measures at different positions on a single unit

A

Positional

32
Q

__________ variation is defined as the magnitude of variation coming from measures of consecutive units

A

Cyclical

33
Q

_________ variation is defined as the magnitude of variation coming from measures separated by a significant amount of time.

A

Temporal

34
Q

What is the objective of the analyze phase review?

A

To show your project sponsor which causes of nonconformities you will focus on during the improve phase.

35
Q

What are 4 deliverables of the analyze phase gate review?

A
  1. Documentation of potential causes (x) considered in your analysis
  2. Charts and other analyses that show the link between the target causes (x) and the critical outputs (y)
  3. Your interpretation of the data and justification of the vital few x’s
  4. Process analysis showing value add and cycle time as required
36
Q

Process for knowing/finding whining x’s have the most effects on the output y

A

Screening

37
Q

Formulating and quantifying the mathematical relationship between the significant x’s and the output y

A

Characterization

38
Q

Discovering where to set the values of the significant x’s to produce the optimal y

A

Optimization

39
Q

Name five characteristics of the six sigma approach

A
  1. Planning the experiment before you conduct it
  2. Exploring the effect of more than one factor at a time
  3. Minimizing the number of required runs in an experiment
  4. Replicating key experimental conditions to assess variation
  5. Accounting for known and unknown factors that you aren’t directly including in your experiment.
40
Q

__________ is the most common six sigma experiment, they can be adapted to provide screening, characterization or optimization information

A

2k full factorial

41
Q

An output that is measured or observed

A

Response variable

42
Q

A controlled or uncontrolled input variable

A

Factor

43
Q

A specific value or setting of a factor

A

Level

44
Q

The change in response variable that occurs as experimental factors change levels

A

Effect

45
Q

Occurs when the effect of one factor on the response depends on, or interacts with the setting of another factor

A

Interaction

46
Q

Gathering data by executing the experiment with a unique pre determined set of levels for each factor

A

Run

47
Q

Replicating/duplicating the entire experiment in a time sequence with a different setup

A

Replication

48
Q

Name the three steps in planning 2k full factorial experiments

A
  1. Selecting experimental factors
  2. Setting the factor levels
  3. Creating the coded design matrix
49
Q

2k full factorial experiments work best with ___ to ____ factors

A

Two to five

**more than five factors - consider fractional factorial experiments

50
Q

2k full factorial experiments use only _____ levels for each input factor.

A

2

**each factor should have a high and low value

51
Q

What are the 4 steps in solution evaluation matrix?

A
  1. Determine evaluation criteria
  2. Assign weights to evaluation criteria
  3. Determine rating scale
  4. Rate solutions and identify best solution
52
Q

________ is an analysis that quickly identifies relative strengths and weaknesses. It is an iterative/repetitive/cyclical process that refines solutions by preserving strengths and minimizing weaknesses.

A

Pugh analysis

53
Q

Name the 8 steps of a Pugh analysis

A
  1. Determine evaluation criteria
  2. Assign weights to evaluation criteria
  3. Populate the Pugh matrix
  4. Select one alternative as the baseline
  5. Rate alternatives
  6. Calculate totals
  7. Analyze results and refine criteria and solutions
  8. Converge on the best alternative
54
Q

Name the four lean six sigma best practices

A
  1. Total productivity maintenance (TPM)
  2. Reliability
  3. Lean operations and visual factory
  4. Overall equipment effectiveness(OEE)
55
Q

The concept of reducing machine variability through excellent maintenance practices that include all departments and all employees throughout the lifecycle of equipment.

A

Total productivity maintenance (TPM)

56
Q

Includes mean time between failures and mean time to repair

A

Reliability

57
Q

Includes principles and concepts of both lean layout and lean inventory

A

Lean operations and visual factory

58
Q

_________ breaks manufacturing performance into three components, (availability,performance and quality) that can be targeted for improvement.

A

Overall equipment effectiveness (OEE)

59
Q

For risk evaluation matrix, typically a _______ risk is best

A

Lower

60
Q

Name the four steps for execute phase gate review

A
  1. Solution development and selection
  2. Pilot testing
  3. Full scale implementation plan
  4. Updated project charter and project plans
61
Q

________ _________ make the operator aware of items in the system for controlling parts and processes during full production.

A

Control plans

62
Q

Name 6 items a control plan should include

A
  1. Process flowchart
  2. Safety characteristics
  3. Relationships between critical x’s and y’s
  4. Identification of gates and/or test equipment
  5. Sample sizes and frequency
  6. Reaction plans to failures
63
Q

_________ ___________ _____________ are step by step descriptions of how to complete a task

A

Standard operating procedures

64
Q

____________ is the process of locking in gains made during the improvement phase.

A

Standardization

65
Q

Name 6 steps in the provide training process

A
  1. Identify personnel to be trained
  2. Determine training assessment method
  3. Provide context using process flow charts
  4. Deliver training using standard operating procedures control charts and reaction plans
  5. Assess training effectiveness
  6. Update personnel training records
66
Q

List 5 steps in the transition ownership process

A
  1. Finalize documentation
  2. Schedule transition meeting
  3. Confirm control plan and training
  4. Execute transition meeting and obtain sign off
  5. Schedule validation check 6-12 months following transition
67
Q

The _______ __________ is a graphic representation of the actions, data, and decisions of the DMAIC project

A

Project storyboard

**primary audience - executive sponsor, project champion, and subject matter experts

68
Q

Name 5 steps in the execute phase gate review

A
  1. Documented process control plan including control charts and reaction plans
  2. Documented procedures or work instructions
  3. Training materials including updated process maps
  4. Documented transition plan
  5. Before and after data on project metrics
69
Q

Variability that affects every production process to some degree and is to be expected.

A

Common cause (natural) variation

70
Q

Variability in a process that can be traced to a specific cause

A

Special cause (assignable) variation

71
Q

Over control of a process that increases variation

  • the error is treating common cause variation as special cause variation.
A

Tampering

Pataky Six Sigma (3 decks)

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