SCMG 337 1-4
What are the 5S's?
1. Sort 2. Straighten 3. Shine 4. Standardize 5. Sustain
Total Quality Management (TQM) Definition
A management approach that focuses all function and levels of the organization on quality and continuous improvement.
What does improve mean in DMAIC?
Confirm impact of key factors on CTQ's. Determine methods for measuring variation, maximum acceptable range of variation, and methods to make processes acceptable.
What does Define mean in DMAIC?
Define problem, the customer of problem, and critical-to-quality attributes (CTQ's) that customer considers most important.
What does DMAIC stand for in six sigma?
Define, Measure, Analyze, Improve, Control It is the 6 sigma equivalent of PDCA
What does analyze mean in DMAIC?
Determine causes of problems and poor performance in those processes; determine key factors causing large or erratic process variation.
What does control mean in DMAIC?
Employ methods to ensure that processes stays within acceptable range
Countermeasures against Toyota's waste - waste of human talent
Employee involvement
Process flow chart Def
For "PC Board Flow" (whatever that means)
What does measure mean in DMAIC?
Identify processes that influence CTQ's. Measure their performance
What is 5s
Initiative for improvement/ Discipline to maintain improvements
1) Cause and effect (fishbone diagram) photo
Looks like a fish
what are Toyota's 7 Wastes
Overproduction Waiting time Non-utilized human talent Transportation Inventory Motion Excess processing
Countermeasures against Toyota's waste - overproduction
Produce only on demand
Pareto analysis def
Seperate the "vital few" from the "trivial many"
histogram definition
Shows distribution or frequency; sometimes in a pattern
What does act mean in PDCA
Take appropriate action --Keep plan and expand it --Revise plan --Dump plan; try something else
Waste-
anything beyond minimum amount of resources (material, labor, parts, time, equipment) absolutely necessary to add value to a product or service
Value added
anything that directly adds to the value of a product or service from the perspective of the customer
3) Histogram photo
bar chart no space in between the bars
6) Pareto analysis photo
bar chart with line
4) Scatter diagram photo
dots on a graph with no line
Scatter diagram def
hows relationships between two variable
What does do mean in PDCA
implement the plan
2) Check sheet photo
looks like excel document
What does check mean in PDCA
monitor and measure results; compare to goals
7) Control charts and run diagrams photo
multiple lines or one over a time period
Necessary non-value added
non value added but necessary and hard to eliminate (planning, scheduling, purchasing, quality control, transportation
5) Process flow chart photo
normal flow chart
What is the goal of DMAIC?
to minimize process variation
Non-value added
waste
Features of TPS— Lean Production -- Integrated product-development process
(design product and production process together; reduce wastes associated with product design; improve overall design process: better, faster, cheaper)
Features of TPS— Lean Production -- Supplier partnerships
(reduce overproduction inventory, defects, waiting, processing; better serve final customer)
what pdca stands for? (Deming Cycle)
- plan-do-check-act - improvement really does occur through PDCA -the search for improvement is continuous -improvement happens through the PDCA cycle
Countermeasures against Toyota's waste - processing
1) Analyze steps 2) Identify and try to eliminate non-value added ones
What are the magnificent seven?
1) Cause and effect (fishbone diagram) 2) Check sheet 3) Histogram 4) Scatter diagram 5) Process flow chart 6) Pareto analysis 7) Control charts and run diagrams
Scrub or shine
1) Cleaning; identifying abnormal or potentially problematic situations 2) If it cant be cleaned, paint or replace it
What does plan mean in PDCA (5)
1) Collect data 2) Define Problem 3) State Goal 4) Develop Solution 5) Prepare Plan
Countermeasures against Toyota's waste - waiting
1) Eliminate sources of waiting: -----Set up time -----Equipment breakdown -----Erratic schedules -----Large batch production -----Defects 2) Discourage busy work so waiting can be identified
Sort and Organize
1) Eliminate unnecessary/unused items 2) Categorize items
Features of TPS— Lean Production (3)
1) Employee empowerment and cross-functional teams 2) Supplier partnerships 3) Integrated product-development process
Countermeasures against Toyota's waste - defects
1) Implement a system to preclude defects 2) Implement a system to immediately identify and rectify defects (source inspection)
Countermeasures against Toyota's waste - motion
1) Improve facility layout 2) Improve process and job design 3) Clean and organize workplace
Control charts and run diagrams def
1) Involves sample inspection 2) Shows limits as determined by statistical formulae 3) Shows process variation 4) Assess whether variation is from random or nonrandom causes
cause-and-effect (fishbone) diagram defintion
1) Maintains focus on the issue at hand 2) Stimulates active search for clauses 3) Motivates data collection 4) Demonstrates high level of understanding
Necessary Non-Value Added examples 7
1) Planning 2) Schedules 3) Purchasing 4) Quality inspection 5) Process/ equipment changeover 6) Equipment preventive maintenance and repairs 7) Transportation
Countermeasures against Toyota's waste - inventory
1) Produce only what is required or demanded 2) Produce in small batches 3) Procure in small batches 4) Follow standard work 5) Eliminate breakdowns
Countermeasures against Toyota's waste - transportation
1) Rearrange facility layout and shorten distances 2) Rearrange stages of the process 3) Use good housekeeping 4) Improve transportation methods
sustain
1) Taking responsibility for maintaining the workplace 2) Discipline must be maintained
Straighten
1)Having a place for everything, and everything is in its place 2) Red tag* Outline
Standardize
1)Having an underlying system or principles for maintaining the first three S's 2)Necessary to prevent backsliding 3)Simple 4)Known 5) Held accountable for
TPS— prototype for Lean Production (7)
1)Pull-type production system 2)Small batch production 3) Small setup times 4)Flexible layout 5) Standard work/operations 6) Workplace organization: visual management 7)Total maintenance (TPM)
Check Sheet definition
1)Unique and customized for every situation 2)Easy to use and interpret 3) Designed by data collectors