yellow belt review Flashcards
what is Heijunka?
process leveling in value stream
what is Kaizen?
make better (cont improvement)
IRS?
Increase efficiency, Reduce Cost, Save time
what is jidoka?
stop the line, machines with human oversight
what does JIT reveal?
exposes problems early
what are the 3 components of the toyota house of quality foundation?
heijunka, SOP, kaizen
toyota house of quality is the ______?
the WHAT
the toyota way is the _____?
the HOW
what is the toyota way?
(2nd house) continuous improvment and respect for people . the How
starting a Lean project involves this very first action…
value stream mapping is the line of departure, it IDs the processes involves
Taiichi Ohno highlights
post ww2 era, initiated the idea of lean ( he did not use the word lean however)
identified the 7 wastes (Muda)
Bill Smith highlights
six sigma organizer (sigma is just math, he structured the process tools). Eng that applied stats to six sigma
Jack Welch highlights
GE exec in mid 80s perfected six sigma and saved 11 billion over 10 years
Vilfredo Pareto highlights
lean is influenced by him. observed that 80% of something is done by 20% of people etc
Walter Shewart highlights
special cause— comman cause analysis. concentrate on the comman causes to reduce waste.
gave us the PDCA model for lean problem solving
Henry Ford highlights
created with the assembly line
Fredrick Taylor highlights
there is only one best way to do something. standardized processes.
W. Edward Deming highlights
TQM pioneer to japan, US business did not want his interference. SOP, process controls etc. Japan post ww2 embraced him and exploded in quality and sales. 1973 us business started paying attention.
Dr Kaoru Ishikawa highlight
founded the Fishbone assessment diagram
cause and effect
Dr. Shigeo Shingo
Poke Yoke (mistake proofing idea) annual Lean award presented in his name
define value added activity
something that changes the shape or form of a product into something a customer s willing to pay for.
other benefits of Lean in addition to the IRS top 3.
lower cycle time, increased associate engagement, lower inventory levels,career pathing, remain comtetive in marketplace
what is DMAIC
define; measure; analyze; improve; control
what are some Improve outputs (from dmaic)
future state VSM, improved matrix, pilot studies
what are some Analyze outputs (fm dmaic)
VA, NVA analysis, id of inputs, statistically test all inputs, validation of critical X’s
what are some Measure outputs (fm dmaic)
VSM, fish bone, dpmo, sigma value, histogram
what are some Define outputs (fm dmaic)
projrct charter, stakeholder analysis, gantt– project schedule, sipoc, voc matrix
what defect percent is 6 sigma?
3.4 defects per million opportunities – considered perfect
the place where value is created….
The Gemba (go see, ask why, show respect)
use of an A3….
strategy, problem solving, budgets, idp/pdp, procurement, etc meant to tell the story, all on one side of a page
Y axis, X axis
value, time
name the 4 basic problem solving approaches
kaizen (just do it action items),
rapid improvement event,
PDC/SA ,
DMAIC DMADV
what is a “problem”?
it is an deviation from the standard, a gap between actual and desired/targetted conditions, an unfulfilled customer need.
3 reason why problem solving is important
- drives Continous improvement
- engages people in the change process
- provides better care and outcomes for our customers
explain the 5 Whys.
in a fishbone diagram concept, asking Why at least 5 times of the current state tends to get to a root cause that can be addressed
3 root cause tools
pareto chart, 5 Whys, Cause Effect diagram
name the 3 rules of zero defects…
never accept a defect; never cause a defect; never pass a defect
list benefits of kanban(6 of them)
its a simple work order of what to work on
replacement info seen at a glance
gives direction based on actual conditions in workspce
prevents extra paperwork
prevents over producing
controls and reduces inventory costs
kanban signals….
low levels of inventory
standization benefits, list some (there are at least 8)
improves safety maintains quality reduces cost increases productivity stabilzes deliveries eliminates waste and simplfiies processes improves employee morale and engagement helps to reveal problems
Mr Ohno said, “ without standards there can be no….”
…. kaizen
motion economy is ,……
seeks to combine, eliminate, reduce and smooth (CERS) motion.
it considers the work place arrangements such as placement of tools, supplies, and equipment to reduce motion
5 S include
sort, straighten, shine, standardize, sustain
3 benefits of 5 S….
IRS
increase efficiency,
reduce waste and clutter,
safety increased
LSS definition!
LSS is a business strategy of creating and sustaining value for a customer by identifying value streams and eliminating waste.
define Value stream…
for s good: from the time the customer places and order until the time the customer receives the product.
3 levels of value streamss
process
door to door
enterprise
Heijunka def…
leveling: creates static work loads to avoid dramatic shifts in swings in production
give 3 types of heijunka…
one piece flow (vs batch and queue)
(push vs) pull at the end of the value stream
fifo
