Terms Exam 2 Flashcards
______ ________ is a data driven problem solving methodology.
Six sigma
What is one hallmark of six sigma maturity?
Unwavering reliance on data
What must you do to get a concentrated stream out of the bottom of a funnel?
You must fill the top abundantly
The __________ phase pinpointed the location or source of problems as precisely as possible and established a baseline capability level.
Measure
The _________ determines and prioritizes root causes.
Analyze
Name 6 tools used for ideas
Brainstorming Nominal group technique Five whys Affinity diagram Multi voting Pairwise comparison
Name 6 tools used for process mapping and analysis
SIPOC map As is value stream maps Relationship matrix Ishikawa (cause and effect) diagrams Cause and effects matrix FMEA
Name 5 tools used for data collection
Attribute (discrete) and variable (continuous) data Single characteristics Paired characteristics (scatter diagrams) Time dependent characteristics (run charts) Observational studies
Raw facts
Data
Form - facts structure relation
Information
Pattern or trend
Knowledge
__________ ____________ analyze the variation in the observed critical output (Y) and identify which variables (X) are the most likely causes of the variation.
Observational studies
___________ control input variables (X) to see the effect on the output (Y)
Experiments
Some experiments are unrealistic or _________
Unethical
In analyzing differences in box and whisker plots _______ __________ implies the input variable (x) has an effect on the output (y)
Significant difference
What type of data analysis tool can you use for continuous input (x) and continuous output (y)?
Scatter plot
What type of data analysis tool can be used for discrete input and continuous output or continuous input and discreet output?
Stratified frequency plots
What type of data analysis tool can be used for discrete input (x) and discrete output (y)?
Table of results
T/F. Correlation equals causation
False
What are the five objectives to perform process analysis?
- Improve understanding of process flow
- Reduce cost
- Identify bottle necks and cycle time problems
- Identify value add activities
- Identify waste
Name 6 tools for perform process analysis
SIPOC Value Stream Mapping Transportation and Spaghetti Diagrams Value added flow analysis Swim lane flow charts Bottleneck analysis - theory of constraints
Munro defines a root cause as what?
A factor that caused a nonconformance and should be permanently eliminated through process improvement.
_________ root causes lead directly to the non conformance
Direct
___________ root causes are a chain of causes and effects that lead to the nonconformance.
Indirect
Name two new tools we have to determine and prioritize root causes
Interrelationship diagram
Multi vari studies
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
Interrelationship diagram
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
Interrelationship diagram
Name the 7 steps in the process for an interrelationship diagram
- Agree on problem statement or research question
- Document each critical input (x) on a post it note
- Assign a unique Id (letter or number) to each post it note
- Arrange post it notes in a large circle on a white board or flip chart
- Look for cause/influence relationships among all ideas and draw relationship arrows
- Tally the number of incoming and outgoing arrows
- Identify visually the key drivers (root causes) and key outcomes
___________ ____________ studies allow you to listen to the voice of the process and identify which inputs (x) are exerting an influence on the output (y)
Multi vari (multiple variable)
Name three major categories of causes (x) of output (y) variation
Positional
Cyclical
Temporal
__________ variation is defined as the magnitude of variation coming from measures at different positions on a single unit
Positional
__________ variation is defined as the magnitude of variation coming from measures of consecutive units
Cyclical
_________ variation is defined as the magnitude of variation coming from measures separated by a significant amount of time.
Temporal
What is the objective of the analyze phase review?
To show your project sponsor which causes of nonconformities you will focus on during the improve phase.
What are 4 deliverables of the analyze phase gate review?
- Documentation of potential causes (x) considered in your analysis
- Charts and other analyses that show the link between the target causes (x) and the critical outputs (y)
- Your interpretation of the data and justification of the vital few x’s
- Process analysis showing value add and cycle time as required
Process for knowing/finding whining x’s have the most effects on the output y
Screening
Formulating and quantifying the mathematical relationship between the significant x’s and the output y
Characterization
Discovering where to set the values of the significant x’s to produce the optimal y
Optimization
Name five characteristics of the six sigma approach
- Planning the experiment before you conduct it
- Exploring the effect of more than one factor at a time
- Minimizing the number of required runs in an experiment
- Replicating key experimental conditions to assess variation
- Accounting for known and unknown factors that you aren’t directly including in your experiment.
__________ is the most common six sigma experiment, they can be adapted to provide screening, characterization or optimization information
2k full factorial
An output that is measured or observed
Response variable
A controlled or uncontrolled input variable
Factor
A specific value or setting of a factor
Level
The change in response variable that occurs as experimental factors change levels
Effect
Occurs when the effect of one factor on the response depends on, or interacts with the setting of another factor
Interaction
Gathering data by executing the experiment with a unique pre determined set of levels for each factor
Run
Replicating/duplicating the entire experiment in a time sequence with a different setup
Replication
Name the three steps in planning 2k full factorial experiments
- Selecting experimental factors
- Setting the factor levels
- Creating the coded design matrix
2k full factorial experiments work best with ___ to ____ factors
Two to five
**more than five factors - consider fractional factorial experiments
2k full factorial experiments use only _____ levels for each input factor.
2
**each factor should have a high and low value
What are the 4 steps in solution evaluation matrix?
- Determine evaluation criteria
- Assign weights to evaluation criteria
- Determine rating scale
- Rate solutions and identify best solution
________ 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.
Pugh analysis
Name the 8 steps of a Pugh analysis
- Determine evaluation criteria
- Assign weights to evaluation criteria
- Populate the Pugh matrix
- Select one alternative as the baseline
- Rate alternatives
- Calculate totals
- Analyze results and refine criteria and solutions
- Converge on the best alternative
Name the four lean six sigma best practices
- Total productivity maintenance (TPM)
- Reliability
- Lean operations and visual factory
- Overall equipment effectiveness(OEE)
The concept of reducing machine variability through excellent maintenance practices that include all departments and all employees throughout the lifecycle of equipment.
Total productivity maintenance (TPM)
Includes mean time between failures and mean time to repair
Reliability
Includes principles and concepts of both lean layout and lean inventory
Lean operations and visual factory
_________ breaks manufacturing performance into three components, (availability,performance and quality) that can be targeted for improvement.
Overall equipment effectiveness (OEE)
For risk evaluation matrix, typically a _______ risk is best
Lower
Name the four steps for execute phase gate review
- Solution development and selection
- Pilot testing
- Full scale implementation plan
- Updated project charter and project plans
________ _________ make the operator aware of items in the system for controlling parts and processes during full production.
Control plans
Name 6 items a control plan should include
- Process flowchart
- Safety characteristics
- Relationships between critical x’s and y’s
- Identification of gates and/or test equipment
- Sample sizes and frequency
- Reaction plans to failures
_________ ___________ _____________ are step by step descriptions of how to complete a task
Standard operating procedures
____________ is the process of locking in gains made during the improvement phase.
Standardization
Name 6 steps in the provide training process
- Identify personnel to be trained
- Determine training assessment method
- Provide context using process flow charts
- Deliver training using standard operating procedures control charts and reaction plans
- Assess training effectiveness
- Update personnel training records
List 5 steps in the transition ownership process
- Finalize documentation
- Schedule transition meeting
- Confirm control plan and training
- Execute transition meeting and obtain sign off
- Schedule validation check 6-12 months following transition
The _______ __________ is a graphic representation of the actions, data, and decisions of the DMAIC project
Project storyboard
**primary audience - executive sponsor, project champion, and subject matter experts
Name 5 steps in the execute phase gate review
- Documented process control plan including control charts and reaction plans
- Documented procedures or work instructions
- Training materials including updated process maps
- Documented transition plan
- Before and after data on project metrics
Variability that affects every production process to some degree and is to be expected.
Common cause (natural) variation
Variability in a process that can be traced to a specific cause
Special cause (assignable) variation
Over control of a process that increases variation
- the error is treating common cause variation as special cause variation.
Tampering
