Lean Six Sigma Black Belt

Force Field Analysis

" A technique for analyzing the forces that will aid or hinder an organization in reaching an objective. An arrow pointing to an objective is drawn down the middle of a piece of paper. The factors that will aid the objective's achievement (called the driving forces) are listed on the left side of the arrow; the factors that will hinder its achievement (called the restraining forces) are listed on the right side of the arrow. "

bivariate distribution

"Also known as a scatterplot, scatter diagram, or scattergram, a graphic representation of correlation accomplished by the simple graphing of the coordinate points for values of the X-variable and the Y-variable"

DMADV

(Define - Measure - Analyze - Design - Verify) A Six-Sigma process that outlines the steps needed to create completely new business processes or products. and verify output meets requirements

Total Productive Maintenance

A Lean equipment maintenance strategy for maximizing overall equipment effectiveness in support of preventing quality problems or downtime while minimizing process interruption.

Standard Work

A concept by which each work activity is organized around human motion to minimize waste. Each activity is precisely described

Design to cost

A concept that establishes cost elements as management goals to achieve the best balance between life cycle cost, acceptable performance, and schedule; under this concept, cost is a design constraint during the design and development phases and a management discipline throughout the acquisition and operation of the system or equipment.

u-Chart

A control chart that plots the number of defects per unit and where sample size varies. More ragged control limits

C-chart

A control chart that plots the number of defects when the sample size is constant

P Chart

A control chart used when sample size varies to plot the proportion or percentage of defectives

Pugh Analysis

A decision matrix that is used when a single option must be selected from several and when multiple criteria are to be used.

Nominal Group Technique

A decision-making technique in which group members write down ideas and solutions, read their suggestions to the whole group, and discuss and then rank the alternatives.

Nonconformity

A departure from quality that is severe enough to not meet a specification requirement. Within org

Interrelationship Digraph

A diagram that places the contributors to a problem in a circle and uses arrows to show the cause-and-effect relationships among the contributors.

Process performance index

A dimensionless number that is used to represent the ability to meet specification limits on a characteristic of interest

t distribution

A distribution specified by degrees of freedom used to model test statistics for the sample mean, differences between sample means, etc. where IT (' s) is (are) unknown

Weibull Distribution

A mathematical distribution showing the probability of failure or survival of a material as a function of the stress

Precision to tolerance ratio

A measure of capability in a measurement system. The smaller, the better. 6 times the estimated standard deviation of the total measurement system variability divided by USL-LSL. <.10 is good and greater than .3 is an OFI

Skewness

A measure of the shape of a data distribution. Data skewed to the left result in negative skewness; a symmetric data distribution results in zero skewness; and data skewed to the right result in positive skewness.

Kruskal-Wallis test

A nonparametric statistical test used to compare three or more unpaired (independent) samples where the outcome is either ordinal or continuous with a skewed distribution.

Exponential Distribution

A probability distribution associated with the time between arrivals

Systematic Sampling

A procedure in which the selected sampling units are spaced regularly throughout the population; that is, every n'th unit is selected.

Quality Function Deployment (QFD)

A process that helps a company determine the product characteristics important to the consumer and to evaluate its own product in relation to others.

Taguchi Loss Function

A proposed model of the cost of nonconformance that penalizes even small degrees of deviation from a target specification.

Prototype

A representation of the actual product in terms of form, fit, and functionality with limitations on functions and/or features

Block Sampling

A sampling technique that involves selecting a sample that consists of contiguous population items, such as selecting transactions by day or week.

pilot run

A short, limited production run usually terminated by elapsed time or quantity produced

chi-square distribution

A skewed distribution whose shape depends solely on the number of degrees of freedom. As the number of degrees of freedom increases, the chi-square distribution becomes more symmetrical.

Model

A smaller physical representation developed on a specified scale

Theory of Constraints

A specific approach used to identify and manage constraints in order to achieve the company's goals.

Process performance

A statistical Measure of the outcome of a characteristic from a process that may not have been demonstrated to be in a state of statistical control

Design of Experiments

A statistical method for identifying which factors may influence specific variables of a product or process under development or in production.

Two-Way Anova

A statistical test that can be used in the analysis of two-factor experiments.

Goodness of Fit Test (Chi Square)

A statistical test that tests whether the data follows a specified distribution or not

One-way ANOVA

A statistical test used to analyze data from an experimental design with one independent variable that has three or more groups (levels).

Kanban

A system that signals the need to replenish stock or materials or to produce more of an item. Made by Toyota's Taiichi Ohno

DMAIC (Define, Measure, Analyze, Improve, Control)

A systematic, closed-loop process for continued improvement that is scientific and fact based

Kano Model

A technique that categorizes customer requirements into three types: 1. Must have- low satisfaction, high dissatisfaction 2. One dimensional- high satisfaction, high dissatisfaction 3. Attractive- high satisfaction, low dissatisfaction 4. Indifferent- low satisfaction, low dissatisfaction 5. Reverse- no satisfaction, high dissatisfaction

Gantt Chart

A time and activity bar chart that is used for planning, managing, and controlling major programs that have a distinct beginning and end.

Tree Diagram

A tool that depicts the hierarchy of tasks and subtasks needed to complete an objective

Affinity Diagram

A tool that helps teams sort verbal data or ideas into categories for further investigation or evaluation.

Process Decision Program Charts (PDPC)

A tool that identifies all events that can go wrong and the appropriate countermeasures for these events

Matrix Diagram

A tool that identifies the relationships that exist between groups of data. Also used to identify strengths in those relationships

Prioritization Matrix

A tool used to choose between several options that have many useful benefits but where not all of them are of equal value

Activity Network Diagrams

A tool used to illustrate a sequence of events or activities and the interconnectivity of such nodes. Helps find the critical path. Aka the arrow diagram

Xbar chart

A variable control chart that is used to depict process average

Internal business processes perspective

All organizational processes designed to create and deliver the customer's value proposition

Work in Progress (WIP)

All the material that has been input into the process but not reached the final stage

simulation

An approach performed usually using a computer software and can be either deterministic or probabilistic by design. Allows team to implement solutions offline

nested design

An experimental design with a within-subjects factor in which different levels of one independent variable are included under each level of a between-subjects factor.

Special Cause Variation

An unusual source of variation that occurs outside a process but affects it. Can be removed or adjusted usually

AIAG

Automotive Industry Action Group

Hoshin Planning

Breakthrough planning where a company develops up to 4 vision statements that indicate where company should be in next 5 years; goals and work plans are developed based on the vision statements; periodic audits are conducted to monitor progress

ANOVA

Compares mean values of a contributes variable for multiple categories/groups

Design for Robustness

Consideration that design must accommodate increased variation in the inputs while still producing the required output within defined specifications.

Kaizen

Continuous improvement that involves all participants.

Attribute Control Chart

Control Chart used to count data in which each data element is classified in one of two categories. p and np charts

Short-run Control Charts

Control Charts used when the data are collected infrequently or aperiodically. They may be used with historical target or target values, attributes, or variable data. Focused on process metrics

S Chart

Control chart that tracks sample standard deviations. used when sample size is greater than 10

Moving Average and Moving Range Chart

Control chart used when data are collected periodically or when it takes time to produce a single item, to dampen he effects of over control, or to detect smaller shifts in the process

Variable Control Chart

Control chart where data to be plotted result from measurement on a variable or continuous scale. Xbar and R Charts

Individuals and Moving Range Chart

Control charts that are used when the sample size is one

NP chart

Control charts that plot the number of defectives/unit and sample size is constant

DMADOV

Define, Measure, Analyze, Design, Optimize, Verify; ensures design is optimized after being designed

Functional requirement

Defines how the product is to perform and under what conditions

DFSS

Design for Six Sigma, a structured approach to developing new products and services that meet customer requirements fully from the outset.

Design for Manufacture

Designers design specifically for optimum use of existing manufacturing capability.

Conventional Tolerances

Determines tolerance in a situation where there are several parts are stacked together

Mann-Whitney U test

Determines whether two uncorrelated means differ significantly when data are nonparametric

RACI Model

Different responsibilities of team members: 1. Responsible- activity participate 2. Accountability- ultimately accountable for results 3. Consulted- must be consulted before a decision is made 4. Informed- must be informed about a decision because they are affected

Dependent events

Events for which the outcome of one event affects the probability of the second event

learning and growth perspective

Identifies the infrastructure and skills needed to carry out business processes, interact with customers, and achieve long-term financial growth; it also helps to identify gaps in capabilities or resources.

Control plan

Living document that identifies critical input and output variables and associated activities that must be performed to maintain control.

Supporting Leadership Style

Low directive and high supportive. Best for capable but cautious performers

Overall Equipment Effectiveness (OEE)

Measuring the effectiveness of all of the equipment of a company based on usage, performance, and production quality.

Consensus Building

Method in which team creates situation or outcome that everyone can agree/live with. Requires skilled facilitator

Porter's Five Forces

Model developed by strategy expert Michael Porter that identifies five competitive forces that influence planning strategies: Bargaining power of customer, bargaining power of suppliers, the threat of new entrants, the threat of substitute products, and the intensity of competitive rivalry

PDCA

Plan - define the problem; Do - implement and collect data; Check - study and analyze; Act - if successful, follow the new standard.

maintenance analytics

Scheduling of maintenance tasks based on data from sensing devices

Performing stage of team building

Team members work together to reach their common goal

Throughput

The amount of output that passes through the process in a specified period of time

Stability of a measurement system

The change in bias of a measurement system over time and usage when that system is used to measure a master part or standard. More stability=variation is in statistical control

Precision

The closeness of agreement among several measurements of the same quantity; the reproducibility of a measurement.

Single-minute exchange of die (SMED)

The concept of setup times of less than 10 minutes, developed by Shigeo Shingo in 1970 at Toyota.

Design for Test

The consideration given during the design stage to improve the testing of a product

Linearity

The difference in bias through the operating range of measurements. More linearity= a constant bias no matter the magnitude of measurement

F distribution

The distribution that models the ratio of two variance estimates; used in ANOVA for obtaining the P-value for testing equality of three or more means

Work in Queue

The material waiting to be processed by one or more steps in the process and is a component of WIP

Discrimination

The measurement systems capability to detect and indicate small changes in the characteristic measured. Aka resolution

Percent Agreement

The percentage of time in an attribute GR&R study has good repeatability, reproducibility, or bias when classifying or rating items using nominal or ordinal scales

Repeatability

The precision under conditions where independent measurement results are obtained with the same method on identical measurement items by the same operator using the same equipment within a short period of time. Aka Equipment Variation or Within-system variation.

Reproducibility

The precision under conditions where independent measurement results are obtained with the same method on identical measurement items with different operators using different equipment. Aka appraiser variation or between conditions variation

Complimentary Rule of Probability

The probability that event A will occur is 1 minus the probability that it will not occur.

Portfolio Architecting

The process of determining which products to produce. The product family will have common modules that will make manufacturing and inventory more efficient and permit mass customization

Takt Time

The rate in time/unit at which the process must complete units in order to achieve demand

Reliability-based maintenance

The scheduling of maintenance based on reliability data, especially if a failure is costly

Periodic Maintenance

The scheduling of maintenance taks based on expected lifetime and when multiple items are more efficiently maintained rather than one at a time.

Condition based maintenance

The scheduling of maintenance tasks are based on operating conditions. i.e. filters being changed more in the summer

P value

The smallest level of significance leading to the rejection of the null hypothesis

Common Cause Variation

The source of variation in a process that is inherent within the process

Design for Maintainability

The systematic consideration of maintainability issues over the product's projected life cycle in the design and development process.

Bias

The systematic difference between the mean of the measurement results and a. reference or true value. Also known as accuracy

Central Limit Theorem

The theory that, as sample size increases, the distribution of sample means of size n, randomly selected, approaches a normal distribution.

Touch time

The time a unit of product is actually being worked on at any step in the process

Cycle Time

The time required to complete one unit from the beginning of the process to the end of the process

TRIZ

Theory of inventive design; principle used when technical problems arise through the use of modern designs

Multiplication Rule of Probabilities

This rule determines the probability of the intersection of two or more events.

Statistical Tolerances

Tolerance determined when the processes are capable and general normal distributions. Ties tolerance to standard deviations

mutually exclusive events

Two events that cannot occur at the same time

Attribute Gage Study

Used to determine the amount of bias and repeatability of a measurement system when the response is an attribute variable (accept or reject). Reference values are known for each part and are selected at equal intervals across the entire range of the gage

Addition Rule of Probability

Used to determine the probability that at least one of two events will occur. Only occurs when A and B are independent P(A or B) = P(A) + P(B) - P(AB)

Noise factor

Variables that cannot be explicitly controlled during the production and/or operation of the product -We use robust designs to reduce these factors

Critical Parameter Management

When critical dimensions are carefully monitored by the use of SPC charts or other data collection and analysis techniques along with responses

Type 2 Error

When we fail reject the null hypothesis when it is false

Type 1 Error

When we reject the null hypothesis when it is true

Norming stage of team building

Where members begin to understand the need to operate as a team rather than as a group

Storming stage of team building

Where members express their own opinions and ideas, often disagreeing with others

Forming stage of team building

Where members struggle to understand the team goal and its meaning for them individually

R Chart

a control chart that tracks the "range" within a sample; it indicates that a gain or loss in uniformity has occurred in dispersion of a production processI. Used when the same size is less than 10

Multivoting

a decision-making tool that enables members to prioritize a long list of ideas with minimal discussion and difficulty

Defect

a departure of a quality characteristic from its intended level or state that occurs with a severity sufficient enough to cause an product to not satisfy. External

Poisson Distribution

a discrete probability distribution describing the likelihood of a particular number of independent events within a particular interval. Used to model the number of defects per unit of time and is the basis for the control limit formulas for the c and u control charts

Tollgate Review

a formal review process conducted the champion who asks a series of focused questions aimed at ensuring that the team has performed during a phase in DMAIC

Binomial Distribution

a frequency distribution of the possible number of successful outcomes in a given number of trials in each of which there is the same probability of success.

Two-Way Anova

a hypothesis test that includes two nominal independent variables, regardless of their numbers of levels, and a scale dependent variable

coefficient of determination

a measure of the amount of variation in the dependent variable about its mean that is explained by the regression equation

Continuous Flow Manufacturing

a method in which items are produced and moved from one processing step to the next one piece at a time

Random sampling

a method of sampling that gives each person in a group the same chance of being selected

Drum-Buffer-Rope

a planning and control system that regulates the flow of work-in-process materials at the bottleneck or the capacity constrained resource in a productive system

Unbiased estimators

a point estimate of a parameter such that the expected value of the estimate equals the parameter

nominal scale

a scale in which objects or individuals are assigned to categories that have no numerical properties

Interval Scales

a scale of measurement in which the intervals between numbers on the scale are all equal in size

Ordinal scale

a scale of measurement in which the measurement categories form a rank order along a continuum

Control Chart

a statistical chart of time-ordered values of a sample statistic

Pull System

a system in which the customer order process withdraws the needed items from a supermarket and the supplying process produces product to replenish what was withdrawn

Contingency tables

a table showing the distribution of one variable in rows and another in columns, used to study the association between the two variables.

regression analysis

a technique for measuring the relationship between two interval or ratio level variables. uses method of least squares

Stratified Sampling

a variation of random sampling; the population is divided into subgroups and weighted based on demographic characteristics of the national population

Fault Tree Analysis

a visual method for analyzing the interrelationships among failures. AND gate has flat bottom. OR gate has pointy top

Process Capability Index

an index that measures the potential for a process to generate defective outputs relative to either upper or lower specifications

Tolerance interval

an interval estimator determined from a random sample so as to provide a level of confidence that the interval covers at least a specified proportion of the sampled population

Systematic Design

applying design principles to the design function, such as value stream analysis and waste elimination

Axiomatic Design

based on the premise that good design is governed by laws similar to those in natural science

Prevention costs

costs associated with preventing defects before they happen

Appraisal costs

costs of the inspection and testing to ensure that the product or process is acceptable

internal failure costs

costs resulting from defects that are discovered during the production of a service or product

external failure costs

costs that arise when a defect is discovered after the customer receives the service or product

Work Breakdown Structure

defines the hierarchy of project tasks, subtasks, and work packages

Normal Distribution

describes a symmetrical, bell shaped curve that shows the distribution of many physical and psychological attributes

Mann-Whitney U test

determines whether 2 uncorrelated means differe significantly when data are nonparmetric (memory: the 'u' reminds you of 'uncorrelated')

Hypergeometric Distribution

distribution of a variable that has two outcomes when sampling is done without replacement

Independent event

events for which the outcome of the second event does not depend on previous outcomes

Lognormal Distribution

generated by the function c^x where X is normally distributed. It's skewed to the right and is bounded from below by zero so that it is useful for modelling asset prices

Coaching leadership style

high directive and high supportive. Best suited for disillusioned learners

Directing leadership style

high directive and low supportive. Best for enthusiastic beginner team members

Kurtosis

how flat or peaked a normal distribution is

Visual Controls

indicators for operating activities that are placed in plain sight of all employees so that everyone can quickly and easily understand the status and performance of the work system

Tolerance Design

involves determining the permissible variation in a dimension

Delegating leadership style

low directive and low supportive. Best suited for self reliant achievers. Also known as Empowering style.

sample correlation coefficient

measures both the strength and direction of the linear relationship between two variables

customer perspective

measures of firm performance that indicate how well firms are satisfying customers' expectations

Financial Perspective

measures of firms' financial performance that indicate how well strategy, implementation and execution are contributing bottom-line improvement

Gage Repeatability & Reproducibility

method for evaluating the variation in the measurement process. Allows for comparison, graphically and analytically, of process to measurement and specification to measurement variation

Poka-yoke

mistake-proofing methods aimed at designing fail-safe systems that minimize human error

Documentation

recording SOPS and work instructions to reduce process variation. Must be kept current

Ratio Scales

scales that have the characteristics of interval scales, plus a meaningful zero point so that magnitudes can be compared arithmetically

Kaizen Event

short term approach to enhancing efficiency that focuses on improving an existing process or an activity within a process

5S

sort, set in order, shine, standardize, sustain. also Seiri, Seiton, Seiso, Seiketsu, and Shitsuke

Knowledge Management

the implementing of systems and practices to increase the sharing of knowledge and information throughout an organization

Process Capability

the inherent variability of process output relative to the variation allowed by the design specification. A capable process is when output always conforms to process specifications

Heijunka

the leveling of production load by both volume and product mix

Conditional Probability

the probability of an event ( A ), given that another ( B ) has already occurred.