LEAN - Six Sigma

What are the Lean Six Sigma three Fundamental challenges

1. Delays, defects, waste and errors 2. Output Variation 3. Monitoring and Control

Measurement Analysis two focuses

1. Repeatability 2. Reproductivity

The Five Steps (5S)

1. Sort 2. Set in Order 3. Shine 4. Standardize 5. Sustain

Define a process

A system that transforms inputs into outputs

The Costs that would disappear if the process that delivers products and services were perfect are referred to as the ____________________________ .

COPQ

Delivering customer value begins with _______________ .

Company Culture

Process monitoring is usually associated with the ___________ stage.

Control

In a ____________ gage R&R study each individual operator measures each part.

Crossed

When asking the question, what is the real problem, the project is very likely to be in the __________ stage.

Define

DMAIC

Define Measure Analyze Improve Control **Six Sigma problem solving framework

Lean focuses on?

Efficiency (minimizing waste and delays)

Lean focuses on ____________ while Six-Sigma focuses on ____________.

Efficiency, Consistency

A Six-Sigma designed process will produce no more than _______ defects per million outcomes.

Mann Whitney

When taking a measurement of an object, if the device used to take the measurement incorrectly measures the object, this is referred to as a _____________ error

Measurement device error

In a ____________ gage R&R study each individual operator only measures one part.

Nested

A process has been redesigned. It is now necessary to determine if it has met its goals. A sample is taken. Assume normality. Which of the following tests will determine if this objective has been met?

One sample test

Six Sigma Focuses on?

Quality / consistency

Six-Sigma Tools used in the problem finding phase?

-Histogram -Pareto Diagram -Fish bone Diagram

Customer Value is represented by what?

-Price -Quality -Serivece

Financial evaluation requires two estimates?

Benefits & Costs

A ____________ study focuses on whether the individuals collecting the data or performing measurement tests are consistent in their measurements.

Gage R&R

X-Y Matrix

Helps to establish which input variables are important. It ranks the importance of each variable aka correlation matrix

Define Cycle Time

Represents the total time it takes to process a person, order, part or assembly from the beginning of a process until it is completed

Consistency across individuals in a Gage R&R study is addressed by the concept of _____________ .

Reproductivity

Identifying a specific location where supplies will be stored is an example of ________________ .

Set in order

Value Stream Map, squares, "D" shapes symbols

Squares= productive operations or value added activities "D" = denote delays Arrows = imply flow Primary purpose is to establish a broad view of a process and to identify waste/delays

An X-bar chart for larger sample sizes, N>25, uses the ____________ to determine the UCL and LCL.

Standard Error of Mean

5S procedures that have been set into place and followed by others is an example of __________________ .

Standardize

The process of ensuring that 5S methods will be used in the future is called _____________ .

Sustain

T or F Lean Six Sigma projects have a clear beginning and end.

True

Define required units of production

a measure of demand

Process Map

a more detailed version of a value stream map. Very Detailed

What represents an Alpha error?

a sample mean outside the LCL or UCL but the process mean has not shifted

Which of the following charts are used in the design of a control process where small samples, N<12, will be taken and the results plotted on a control chart?

x-bar and R-chart

Carry-over effect

The problem with Crossed Gage R&R. It Occurs when the experienced gained by the operator 1 when measuring part 1 carries over and influences the operators's measurement of part 2

Reproducitivity

terms suggests the approach where several people undertake the same test to rule out human error in measuring an object

T or F The Voice of the Customer must be accommodated by the Voice of the Process.

True

T or F The objective of Six Sigma is to deliver near-perfect products and services.

True

T or F The project charter, when approved by management, formally authorizes a project.

True

T or F The quality of the product or service delivered by a process is related to the voice of the customer.

True

T or F To meet quality objectives, Six Sigma sets targets and measures process outcomes against there targets.

True

T or F Customer value must be defined from the customer's perspective.

True

Continuous improvement focuses on...

small changes to established processes.

Y = f(x)

Y represents the process output x represents the the process input

Nested Gage R&R study

each operator only measures one part. The disadvantage to this strategy is that it may require many more operators. (testing air bags example)

T or F Sustaining a lean organization is not difficult as evidenced by the performance of General Motors since the 1950s.

False To the contrary, sustaining a lean culture is a major management challenge.

5S focuses primarily on _______________ .

increasing efficiency

Crossed Gage R&R Study

parts are sampled from a process and several operators are selected to participate in the measurements

T or F All products should be designed in such a way as to deliver perfect performance.

False

T or F Carefully designed processes should not deviate at all from a target.

False

T or F Customer-focused cultures are actually more common than one would expect.

False

T or F It is possible to design a process with no variation in output.

False

T or F A bottom-up approach to improving process performance is most commonly associated with an organizational culture that emphasizes quality, efficiency and customer value.

False It must be top down, an approach that requires top management support.

Which of the following p-values, associated with the coefficient of an independent variable in a multiple regression model suggests significance of that variable at the 0.05 level?

0.01

Takt Time

A German phrase referencing the rate at which a finished product needs to be completed in order to meet customer demand. (its an average)

CTQ

Critical to Quality

To justify the approval of a project, a plan must be established that covers at least 4 important catergoies....

1. Business Case 2. Charter 3. Metrics 4. Financial Evaluation and Benefits

What are the 4 Disciplines for a LEAN Company

1. Clear Direction 2. Enabling Contribution / Work Force 3. Customer Value 4. Discover Better Ways

The Two types of Gage R&R studies?

1. Crossed 2. Nested

Using the concept of 5S, Items can be sorted into three groups

Always used, sometimes used and never used

Two Strategies for sorting

1. by product families 2. or into 3 groups

Four Principles to Kanban

1. use a visual device 2. Limit amount of work that must be done from start to finish 3. Focus on a smooth process flow 4. Continuous improvement

A Six-Sigma designed process will produce no more than _______ defects per million outcomes.

3.4

Gage R&R Study

A formal analysis to uncover the extent of the measurement problem

Define 6 Sigma

A highly disciplined process that focuses on developing and delivering near-perfect products and services

Kanban

A tool developed by Toyota for just in time approach to scheduling and managing operations

The quality of parts, assemblies and products is related to _________ .

Critical to Quality

The length of time from the beginning to the completion of a work process is called _________________ .

Cycle time

T or F Designing efficient processes often takes less time than designing inefficient ones.

False

T or F The more layers there are in a management structure, the more likely it will be for an organization to succeed in developing a lean processes.

False

T or F For most Lean Six Sigma projects, financial evaluation only requires an estimate of the benefits to be achieved.

False Cost estimates are always necessary.

T or F Words such as 'improved results' and 'shorter waiting periods' are often effective metrics by which to gauge the success of a project.

False Metrics need to be concrete not abstract.

T or F The concept of measurement analysis is primarily related to the Analyze stage of the DMAIC Cycle.

False Related to the Measure and Control

T or F Business cases that are written to justify the approval of a Lean Six Sigma project require detailed budgets and schedules.​

False Rough estimates are usually satisfactory for a business case

T or F Business cases for Lean Six Sigma Projects must include full technical descriptions of every step in the project process.

False The business case is a overview of the project.

Define Distribution of Sample Means

The distribution that describes the way in which sample means of a certain size are distributed about the population mean

When several individuals measure the same object but each one records a different result this can be attributed to ____________________ .

Human error

Benefits / Cost Ratio details

If greater than 1, approve project If less than 1, no approval

The Cost of Poor Quality is defined as the ______________________________.

Internal and external costs resulting from the failure to meet process requirements

Define Kaizen

Japanese word suggesting continuous improvement

Push and Pull Forecast

Push - systems that driven by forecast Pull- systems that are driven by demand

Consistency associated with a single individual in a Gage R&R study is addressed by the concept of _____________ .

Repeatability

Which of the following Six-Sigma tools is most useful when identifying outputs and inputs.

SIPOC Diagram

SIPOC Diagram

Suppliers -> Inputs -> Process -> Outputs -> Customers

What suggests that as a process shifts farther and farther away from its target, the cost to the company grows larger and larger..

Taguchi Loss Function

The shortcut formula used to establish the LCL and UCL in an R-chart requires which of the following preliminary steps to compute the value of the average range that will be used as the centerline of the chart.

Taking 5 or more preliminary samples, computing the range of these samples by subtracting the lowest result from the highest result, then computing the average of these ranges.

Upper and Lower Control Limits for large samples are commonly set at plus or minus _________standard Errors of the Mean from the center line or target of the process control chart.

Three

T or F A Metric is a formal and measurable goal for a Lean Six Sigma project​

True

T or F A SIPOC diagram does not include delays and other measures of inefficiency.

True

T or F About 75 percent of Fortune 500 companies utilize the concepts of Six-Sigma.

True

T or F DMAIC is a framework that helps to ensure an orderly and logical flow from the beginning of a Six Sigma project to its end.

True

T or F Organizational culture defines the environment within which Lean Six Sigma initiatives can succeed or fail.

True

An S-Chart is used to monitor process ___________ when the size of the sample, N, is greater than 12.

Variation

The standard deviation measures the ______________ in a dataset.

Variation of data

VOC

Voice of the customer

VOP

Voice of the process

Define Critical to Quality

the specification of product or service capabilities or attributes that are necessary to meet customer expectations

Define available time for production

the total number of hours that will actually be devoted to processing

T or F Data collection is a primary activity associated with the Measure phase.

true

When the mean of a normal distribution is 10 and its standard deviation is two, ninety-five percent of the data points within the distribution will fall between plus and minus ______________ standard deviations from the mean.

two