Unit 1 Lean & Six Sigma Introduction

Question 1

Lean and six sigma are ways to improve

Answer 1

customer value

Question 2

What is Lean?

Answer 2

Lean is a set of concepts and tools, the application of which creates the most value while consuming the least resources and eliminates waste by reducing costs in:

• the overall production process
• the operations within that process
• the utilization of labor
• producing and carrying inventory

Question 3

What is Lean?

Simpler definition

Answer 3

“A manufacturing philosophy that shortens the time line between the customer order and the shipment by eliminating waste.”

Question 4

Henry Ford, 1926

Answer 4

“One of the most noteworthy accomplishments in keeping the price of Ford products low is the gradual shortening of the production cycle. The longer an article is in the process of manufacture and the more it is moved about, the greater is its ultimate cost.”

Question 5

Lean is about…

Answer 5

reducing waste, for example, by eliminating non-value added steps in a process.

Question 6

What is Six Sigma?

Answer 6

Six Sigma is about reducing variability and defects.

Six Sigma applies statistical tools to business problems.

Question 7

Need both Lean and Six Sigma to create

Answer 7

customer value

Question 8

Lean and Six Sigma

Answer 8

work together.

Question 9

Lean focuses on the

Answer 9

mean

Question 10

Lean focuses on

Answer 10

reducing flow time

Question 11

Six sigma focuses on

Answer 11

reducing variability in flow time

Question 12

5 Steps in Lean

SIMPA

Answer 12

• Specify Value
• Identify Value Stream
• Make it Flow
• Pull
• Always Improving

(Repeats in a cycle)

Question 13

DFSS=

Answer 13

Design for Six Sigma.

-For designing new processes.

Question 14

DMAIC

Six sigma

Answer 14

Define
Measure
Analyze
Improve
Control
-for improving existing processes

Question 15

DMAIC is for

Answer 15

improving existing processes

Question 16

DFSSis for

Answer 16

designing new processes

Question 17

5 Steps in Six Sigma DMAIC

Answer 17

Define
Measure 
Analyze
Improve
Control

Question 18

Why do we need Lean AND Six Sigma?

Answer 18

• Lean reduces Non-Value Added steps
• Six Sigma improves quality of value added steps
• -Lean Six Sigma drives quality, speed, and cost simultaneously

Question 19

Lean and six sigma are

Answer 19

complementary

Question 20

Lean Goal

Answer 20

remove waste

Question 21

Six Sigma Goal

Answer 21

reduce variation

Question 22

Lean focus

Answer 22

flow focused

Question 23

Six Sigma focus

Answer 23

problem focused

Question 24

Lean benefit

Answer 24

reduced cycle time

Question 25

Six Sigma benefit

Answer 25

uniform process output

Question 26

Lean Concepts and Tools

Answer 26

Value Stream Map.
5-S
Setup Reduction.
Cell Layout
One Piece Flow.
Pull System.
Kanban.
Visual Control.

Question 27

Six Sigma Concepts and Tools

Answer 27

DMAIC Process.
Statistical Tools
FMEA
Cause and Effect Analysis
Gage R&R
Root Cause Analysis
DOE

Question 28

Barriers to Implementation of Lean and Six Sigma

Answer 28

• Culture Limitations
• Knowledge Limitations
• Management Limitations

Question 29

Culture Limitations - Barriers to Implementation of Lean and Six Sigma

Answer 29

• fear
• time pressure
• resistance to change
• lack of trust
• poor communication

Question 30

Knowledge Limitations - Barriers to Implementation of Lean and Six Sigma

Answer 30

• lack of training
• lack of knowledge among managements
• lack of team and meeting skills

Question 31

Management Limitations - Barriers to Implementation of Lean and Six Sigma

Answer 31

• lack of leadership
• lack of management commitment
• lack of hands-on involvement