Week 6 - 6 Sigma Quality

Question 1

How has lean six sigma evolved over time? (8)

Answer 1

• 1795 - Gauls introduces the concept of the normal curve
• 1913 - Henry Ford introduced the assembly belt in his factories
• 1920s - Walter Stewart works on three sigma and defects
• 1950s - Toyota production system is developed, a trigger for lean
• 1950s - Shiego Shingo introduces SMED and pokayoke
• 1986 - Motorola invent the six sigma quality improvement process
• 1980s - Lean manufacturing makes its way to the west
• 1990s - GE develop six sigma as a management approach

Question 2

What does DMAIC stand for?

Answer 2

• D - Define critical outputs and identify gaps for improvement
• M - measure the work and collect process data
• A - analyse the data
• I - Improve the process
• C - Control the new process to make sure new performance is maintained

Question 3

How does six sigma work? (Funnel effect)

Answer 3

• Starts of with 30-50 input variables which are narrowed down to eventually key process input variables
• This will then lead to improved processes

Question 4

Who are the different people that make up a six sigma team? (8)

Answer 4

• Division deployment champion
• Executive
• Process owner
• Sponsor
• Team members
• Project leader (black or green belt)
• Financial controller
• Master black belt

Question 5

What does a division deployment champion do?

Answer 5

Define strategic objectives

Question 6

What does an executive do?

Answer 6

Owns vision, direction, integration and results

Question 7

What does a process owner do? (2)

Answer 7

• Implements and sustain improvements
• Identify future project

Question 8

What does a sponsor do? (2)

Answer 8

• Plays an active part by supporting the team
• Identify transverse projects

Question 9

What does a team member do?

Answer 9

Provide process expertise and takes part in the project

Question 10

What does a project leader (black or green belt) do?

Answer 10

Manages the project

Question 11

What does a financial controller do?

Answer 11

Measures, approves and monitors financial savings

Question 12

What does a master black belt do?

Answer 12

Coaches the project manager on how to use the tools and methods

Question 13

What are the tools used to gather & measure data in six sigma? (2)

Answer 13

• Check sheets
• Pareto charts

Question 14

What are the tools used to analyse and improve in six sigma? (4)

Answer 14

• Histograms
• Scatter diagrams
• Cause-and-effect diagrams
• Flowcharts

Question 15

What is the tool used for control?

Answer 15

Statistical process control

Question 16

Example of a histogram

Answer 16

Question 17

Definition of a cause and effect diagram

Answer 17

Is a tool that identifies process elements that might effect an outcome

Question 18

What is the focus for six sigma?

Answer 18

Focus on reducing variation to solve process and business problems

Question 19

What happens in the define stage of DMAIC? (3)

Answer 19

• Define the process
• Ask who the customers are and what their problems are
• Identify key characteristics important to customers and the supporting processes

Question 20

What happens in the measure stage of DMAIC?

Answer 20

Collect data in alignment with measurement systems

Question 21

What happens in the analyse stage of DMAIC?

Answer 21

Raw data is converted into information that provides insights into the process including identifying the fundamental and most important causes of the defects or problems

Question 22

What happens in the improve stage of DMAIC?

Answer 22

Solutions to problems are developed and then assessed in terms of how impactful they are

Question 23

What happens in the control stage of DMAIC?

Answer 23

Is about sustaining the improvements