Six Sigma

tree diagram

A tool that shows the linkages between the critical outputs during a DMAIC project

What is a top box score

% Of respondents Who check the top box or highest level available.

Nine parts of the implementation plan

1. Actions -what specific actions will be taken 2. Responsibilities-who is responsible for each action 3. Schedule-when will the action be be taken 4. Cost/benefit analysis-what are the costs and benefits of the actions 5. Measures-what will be measured before, during, and after implementation 6. Risk assessment-what are the risks associated with the actions 7. Contingency plan-what is Plan B 8. Communication plan-what is the communication plan 9. Educational plan-what is the education plan

10 components of six sigma

1. Active senior leadership 2. System view of the organization 3. Expectation of significant results 4. Customer-focused process management 5. Use of special performance measures (e.g., Process Sigma) 6. Use of specialists ( e.g., black belt & master black belt 7. Rigorous use of best known methods ( e.g., DMAIC, DMADV) 8. Rigorous application of best practice tools (e.g., Impact Wheel) 9. Use of six sigma to develop leaders 10. Significant investment in time and money

Six parts of a project objective

1. Identified process/issue 2. Progress measure 3. Baseline for The progress measure 4. Desired direction for the progress measure 5. Target for the progress measure 6. Deadline for achieving the target

Six types of projects of Six Sigma

1. Quick hit-implement an obvious action immediately 2. Rapid Action-identify a small scope solution during several working sessions and manage implementation. Designing, improving or standardizing 3. Lean Project- improve the capability of a process work area or flow to create distinctive value for customers by identifying and eliminating waste 4. Design Project-design or radically redesign a system, process, product, or service 5. Discovery project- thoroughly understand the as is situation and identify strategic issues and opportunities. No idea what to do. 6. Standardization project - create test deploy manage and periodically review standard or a bundle of standards. 7. Improvement project - solve complex organizational problem through the work of a formal team using a structured improvement method like DMAIC

10 Prioritization Techniques

1. Vision enabling- does the task help the organization move toward the vision? 2. Triage- the assignment of degrees of urgency to decide the order of treatment 3. Affinity and relations diagrams. Affinity sort opportunities of the groups. Relations follow and track relationships between groups. 4. Ranking 5. Voting 6. Point distribution 7. Decision matrix ( criteria based decision making) 8. Cost/benefit analysis 9. Conceptual impact wheel

If I have a success rate of 25 percent and I want to increase it to 75 percent what is the magnitude of improvement

3X

Basic lean topics

5S and standardization, Genchi Genbusu, Hansei & Reviews, improvement culture, inventory control, mapping workflows, mistake proofing, quick changeover, PDSA & Blitzes, process control plans, Pull & logical flow, types of waste, suggestion systems, value & VOC, Visual management

Hansei

A Japanese word meaning reflection.

Pareto Chart

A bar graph whose bars are drawn in decreasing order of frequency or relative frequency.

PDCA

A continuous improvement model of plan, do, check, act.

Ohno Circle

A formal technique for observing work firsthand

What is an affinity/relations diagram

A matter consisting of first creating an affinity diagram and then creating a relationship diagram this method is useful for brainstorming output variables input variables a common application is to first identify an open variable and then brainstorm possible important variable clearly defined the problem silent brainstorm potential root causes sort the ideas into groups name the groups.

Tollgate review

A meeting to learn as much as you can and reach consensus on a positive way forward

A3 Report

A one page report that tells the story of an improvement activity

Kaizen blitz

A small scale, small scope, short-term formal and probably activity.

Scope

A statement describing what "is and out of bounds"for a project

What are the key components of an implementation plan?

Actions-what specific actions will be taken? Responsibilities-who is responsible for each action? Schedule-when will the actions be taken? Cost/benefit analysis-what are the costs and benefits of the actions? Measures-what will be measured before, during, and after implementation? Risk assessment-what are the risks associated with the actions? Contingency plan-what is Plan B? Change strategy-what is the organizational change strategy? Communication plan-what is the communication plan? Educational plan-what is the education plan?

What is the Jimi Hendrix rule

Aim high and stay high as long as you can.

What is an integrated flowchart

Also called a swim lane flow charts are neutral tool in the measure. Also known as a process flow diagram a graphical tool that the pics distinct steps of the process in sequential order the basic idea is to include all of the steps of a critical importance to the process. For example customer has issue since issue to customer service customer service checks for a fix if there is a fix they send it directly back to customer if not then they send request on to other areas for fix etc. The charts are used to visualize a process.

Standard

And agreement established for an object, performance, capability, arrangement, state, action, sequence, method, procedure, responsibility, duty, 30, way of thinking. For the purpose of unification and simplification so that profit or convenience maybe obtained with fairness among the people concerned.

Focus area

Another name for a strategy

Strategy

Areas of focus developed from looking at the data gathered From the project objective of the define step. Strategies are mini project objectives or focus areas.

What are some tools for generating solutions? What tool can be used to generate thousands and thousands of ideas in just a few minutes?

Brainstorming Pilot testing FEMA Pareto Charts Idea Box (can create thousands of solution options using a simple table)

What is the fish diagram? What's another name?

Cause-and-effect diagram well known root cause analysis tool utilize the structure of brainstorming to capture root cause ideas from every participant some of the typical because categories could include people, Quitman, information, methods, environment, measurement, procedures, tools and materials.

What are the rules of the project team

Champion, - lead creation of the charter, create positive tone, keep team focused. Team members -attend meetings and training, fully participate, inform and educate members. Process Owner -stay informed, be involved when necessary, be accountable for results Team Leader- manage the team, plan coordinate meetings, focus the team, Coach -facilitate the team, coach and educate, assure methodology is followed

Name two different ways to collect and display data

Data collection checksheet, concentration diagram.

DMAVD

Define Measure Analyze Design Verify Project methodology of six sigma. Used for projects into creating new product or process designs.

Name 3 to 5 tools for each DMAIC step

Define-team roster, ground rules, target setting, project charter, linear flowchart, Key player map Measure-spaghetti diagram, integrated flowchart, cost/benefit analysis, tree diagram, Control chart Analyze-brainstorming, surveys, scatter diagram, hypothesis testing, relations diagram, DOE Improve - ranking and voting, idea box, mistake proofing, brain storming, implementation plan Control-Control plan, audit plan, storyboard, standardization, before and after analysis

FMEA

Failure Mode and Effects Analysis. (Risk analysis). Useful tool for evaluating potential solutions. Failure modes or problems are anticipated for each best potential solution and there six predicted. Each problem is that evaluated in terms of severity of the problem, how frequently the problem will occur, and how Easley the problem can be detective.

Describe the importance of qualifying the financial impact of the project. What are the guidelines, how is it calculated?

Financial impact equals net income profit/cash flow. Hard dollars equal actual money soft dollars equal happier employees etc. Soft dollars are hard to quantify.

Mistake proofing

Formal activity to prevent errors from occurring

What is the theory of improvement

Fully formed theory has three parts. Think through all three parts. If we take these actions it will lead to these results and this is why.

What is asked during the project review?

Identify the benefits that were realized, identify difficulties that were experienced, capture and spread the lessons that we learned.

What are some ways of integrating lean?

Just in time, Pull system., Mapping flows and value streams, types of waste, 5S framework, inventory control, mistake proofing, quick changeover, visual management, suggestion systems, rapid test of change.

Components of the management system

Leaders better be right bottom of improvement-anyone, anywhere, anytime-hey I have an idea what to do! Continuous improvement in day-to-day operations. Strategic Planning Items; Mission, vision, values and strategies. Stakeholder needs, strategic objective, Key processes, organizational performance dashboard. Strategic improvement cycle; build/revise project portfolio, execute portfolio projects, conduct portfolio review, repeat.

Iterative learning

Method of tracking control for systems that work in repetitive mode. Examples robot are manipulators, chemical that's processes. A methodology that tries to address the problem of transient response performance for systems that operate repetitively.Suitable for systems that are able to repeatedly complete several tasks for a fixed time interval. PDSA

What needs to be kept in mind when setting targets?

Need to know baseline., what the idea is what's the best anyone has ever done? What's the return on investment and risk? What's the deadline? What are the resources? Is MOI realistic? Content/necessity and history

Describe the PDSA cycle. Show how DMAIC fits into it.

Plan, Do, Study, Act. First identify expected results and develop a Plan. Do the plan (change). Study adherence to the plan and the results. Act on the lessons learned. End of cycle options scrap and start over, OK but needs improvement so go through cycle again. Works great successful!

Rapid Test of Change

Occurs when at least two iteration of the PDSA ( plan, duty, study, act) Cycle have been conducted in a one-week time period to text a localized improvement idea within a work unit

Seven types of brainstorming

Open brainstorming Silent brainstorming Structure brainstorming Reverse brainstorming Analogy brainstorming Affinity/relations diagram

Eight types of waste

Overproduction, waiting, unnecessary transport, excess inventory, overprocessing, unnecessary movement, defects. ( Tim Wood)

Questions you should ask in each step of the PDSA cycle

PLAN; what is the proposed change? How are you measure the result of the change? What is the baseline level of performance? What results you predict from your change? What is your theory of improvement? Who will be impacted? How do you plant more than one test? Have you identified potential risks? DO; What did you observe are conducting the test change? Who is affected by the test change? What are the effects? Have you documented your actions? Did you notice any factors are conditions that might affect final results? STUDY; did you follow the plan? If not, why? What were the actual results? How many actual results compare with your predictive results? Can you explain the deviations? Can you quantify the impact some quality, safety, service, cost, net income,? What went well and what didn't go well? ACT; what actions will you take based on what you learned? How are you communicate your findings? Will there be another test of change? If yes, when? What controls will you put in place if the changes were successful?

What are the four components of a process control plan

Process flow chart, List of measures, data collection details, contingency or response plan

pull systems

Production approach were Work is triggered by customer demand

What are the types of projects?

Quick hit-implement an obvious solution immediately Rapid action-identify a small scoop solution during several working sessions over two weeks to three months and manage its implementation. It could be designing improving or standardizing. Lean project-improve the capability of a process, work area or flow to create distinctive value for customers by identifying and illuminating waste. Design project-design or radically re--design a system, process, product, or service. Design for six sigma. Discovery project-thoroughly understand the as is situation and identify strategic issues/opportunities. Just investigation. Improvement project-solve complex organizational problems through the work of a formal team that uses a structured improvement method like DMAIC over six months to two years.

What are some types of resistance to change? How can they be overcome

Resistance is emotional it is indirect expression of discomfort due to fear of loss of control or fear of vulnerability. Extended confusion, can you explain that to me again? Delay, I'm really busy right now maybe later. Defiance. I don't like it and I won't do it. Denial, I don't think there really is a problem. Malice compliance, I'll follow your new procedure to the letter. Whispered, these changes will lead to layoffs. Too easy acceptance, great idea thank you for coming. Deflection, I agree there is a problem but not in my area. Silence.

What is the spaghetti diagram and what is it called that? What is another name for it

Spaghetti diagram visually plots the path of movement through a process. Charts are used to analyze the distance covered going back-and-forth to the same place the wasted time in motion or transportation. Spaghetti charts are useful to read design the layout reposition of equipment in order to reduce unnecessary walking time and fatigue. xxxxxxxx

SDSA

Standardize, do, study, act

What does it mean to be in statistical control? What is a control chart?

Statistical control means data is stable consistent predictable and within limits. In order to have confidence that you have statistical control you need to have at least 20 plotted data points over time. If data points are within statistical control, you can somewhat predict what will happen. Control chart is a run shirt with the addition of three lines the centerline, and upper control limit, and the lower control limit. I control chart allows you to monitor performance overtime and determine whether special causes the variation exist.

Who is Edward Deming

Statistician, , Author, lecturer, professor and consultant. He taught top management how to improve design ( and thus service) , Product quality, testing, and sales through various methods, including the application of statistical methods

What is the four student model? Who created it?

The expected results, the plan. Two boxes next to expect results example failed exam, past exam. The plan two boxes underneath missed class, attended class. For options; A - attended class and passed. B - missed class and passed. C- attended class and failed. D- missed class and failed. Learn as much as we can. Developed by Dr Noriaki Kano

Theoretical Performance Level

The level of performance it is impossible to go beyond without a fundamental breakthrough in knowledge or technology. Also considered the best anyone has done for an extended period of time.

Target

The level of performance project team is expected to reach by the project deadline. Expected results.

What is meant by five whys?

The practice of asking why repeatedly whenever a problem is encountered in order to get beyond the obvious symptoms to discover the root cause. Why did the machine stopped? there was an overload of the fuse blew. Why was there an overload? The bearing was not sufficiently lubricated. Why was it not duplicated? Lubrication pump is not pumping sufficiently. Why was it not pumping sufficiently? The shaft of the pump was worn and rattling. Why was the shaft worn out? There was no strainer attached and the metal scraps got in.

Process Control Plan

The premiere tool for standardizing, managing, and improving work processes and procedures. Usually consists of a process flowchart, list of measures, data collection details and a contingency or response plan.

Standardization

The systematic activities of establishing and utilizing standards.

Ideal Performance Level

The ultimate or ideal level of performance

What is a conceptual impact wheel?

Tool for anticipating the consequences of an implemented solution. The impact will allow his consequences to be anticipated and the effects of those consequences positive or negative to be predicted. Potential solutions are often discarded once subjected to an impact wheel. And impact will consist of a cost/benefit and risk analysis simultaneously.

What are the six major mapping tools?

Value stream map, High level linear flow chart, SIPOC diagram, Process activity flowchart, Integrated deployment flow chart Work flow (spaghetti) diagram

What is meant by voice of the customer? How does one conduct a needs profile

Voice of the customer(VOC) is a term used in business in information technology to describe the in-depth process of capturing a customers expectations preferences and aversions. Surveys, focus groups, interviews, observation. Which focus on the customers experiences with current products or alternatives within the category under consideration. Need statements are than extracted, organize into more usable hierarchy been prioritized by the customers.

What are the nine components of a project charter

What are you trying to accomplish(project objective), What measures will be impacted? What people will be impacted? Scope in bounds? Scope out the bounds? Business case( why, why now). Expected benefits? Risks of doing the project. Risks of not doing the project.

What are the 5W and 2H questions?

What is to be standardized? Why does it need to be standardized? Who should be involved in the standardization? When will the standardization occur? How much will it cost to standardize? How long will it take to standardize?

What are the 4W questions

Who, when, where, what. Useful to view the problem from for other perspectives by doing this able to focus. When does the problems occur? Where is the problem occurred? Are there different types of problem? Which individuals or groups are involved?

DPMO

defects per million opportunities

DPO

defects per opportunity or (DPU)/(total defect opportunities)

DOE

dyspnea on exertion

PDSA

Plan Do Study Act A four step method to test an improvement or innovation idea

Four sections of the Toyota production system

1. Long term philosophy. Base your management decisions on a long-term philosophy even at the expense of short-term financial goals 2. The right process will produce the right results. 3. Add value to the organization by developing people and partners. Grow leaders, develop exceptional people. 4. Continuous problem solving drives organizational learning. Go see for yourself to understand, make decisions slowly considering all options, become a learning organization reflection and continuous improvement.

DMAIC

Define-trying to accomplish what Measure-where should we focus Analyze-what are root causes Improve-what solutions to use Control-what controls do we need to sustain performance A six-sigma process: define, measure, analyze, improve, and control. Used for projects in and improving in existing business process.

What is the essential question for each of the DMAIC steps

Define-what are we trying to accomplish? Measure-where should we focus, where are our strategies? Analyze-what are the root causes? Improve-what solutions should we implement to address the root causes? Control-what standards and controls should we implement to sustain the new performance level?

Describe the components and structure of an Improvement tree

Defined the project objective (DEFINE). Develop three strategies ( MEASURE). For each strategy define one or more root causes. (ANALYZE). Develop several solutions for each root cause (IMPROVE). Develop standards and controls for solution (CONTROL). Identify quick hits (RTOC) at each step.

Operational Definition

Definition of a word or concept everyone understands. To ensure there is consistency in collection and interpretation of data

How can you keep ideas flowing? Name several solutions or suggestions systems

Diary, suggestion box, PDC a board, problem tracking for tracking salt and Ansell problems sorted into minor major and critical, Internet

DVF model

Dissatisfaction x vision x first steps > resistance. Dissatisfaction with the current situation: pain,threat current performance service gaps must be shared but not everyone has the same dissatisfaction. Vision of a positive, compelling future state: clearly stated and understandable to everyone, consistent, ennobling, challenging, accessible. First steps in the direction of the vision: Practical plan with attainable steps. How we might behave with one another. Communicated. Resistance to change: always present when change occurs.

Six Sigma

Organized parallel-meso structure to reduce variation in organizational processes by using improvement specialists, a structured method and performance metrics with the aim of achieving strategic objectives. Disciplined, data-driven approach and methodology for eliminating defects. Developed by Jack Welch, By Motorola six to improve the quality of process outputs by identifying and removing causes of defects/errors and minimizing variability in manufacturing in business processes. Each six Sigma project carried out within an organization follows a defined sequence of steps and has qualified financial targets. Cost reduction and/or profit increase. Six sigma doctor in asserts that continuous efforts to achieve a stable and predictable process results are vital importance to business success. Manufacturing and business processes have characteristics that can be measured analyzed improved and control. Achieving sustained quality improvement requires commitment from the entire organization. Features that fat six Sigma a part from previous quality improvement initiatives include a clear focus on achieving measurable and quantifiable financial returns from any six Sigma project. And increased emphasis on strong and passionate management leadership and support. A special infrastructure of champions black belts master black belt green belts to lead and implement a six Sigma approach. A clear commitment to making decisions on the basis of viable data rather than assumptions and guesswork.

Name two tools that can be used to verify root causes.

Passive learning: regression analysis, Chi-Square, etc. Aggressive learning: DOE

What are tollgate questions?

Reviews at the end of each step of DMAIC. To ensure team members understand the roles. Lessons learned why it's important. usually asked by champion.

What are the components of risk analysis?

Risk assessment, risk management and risk communication

SIPOC

Suppliers, Inputs, Process, Outputs, Customers. A diagram that depicts high-level critical information about a process on one page.