Six Sigma and Lean: Foundations and Principles

What types of activites does the Lean methodology focus on?

Streamline and improve processes Eliminate waste Identify and add value

In which situation is Kanban-pull being used?

An automated e-mail message is sent to a glass company when supplies at a bottling company are getting low. A light in the paper room flashes when more paper is required in the print room. When a bin of to-be-processed applications has three left in it, clerks signal for more to be added empty containers are placed on a conveyor system and sent to the supply room to be replenished

What are some specific goals of the Six Sigma methodology?

Lower an organization's overall operating costs Improve customer satisfaction

Place the events in the evolution of continuous improvement methodologies in chronological order. Statistical process control or SPC The Plan, Do, Check, Act cycle or PDCA The Baldridge Criteria for Performance Excellence ISO 9000 Quality

1. The Plan, Do, Check, Act cycle or PDCA 2. Statistical process control or SPC 3. Quality circles 4. ISO 9000 5. The Baldridge Criteria for Performance

Sequence the key developments in the evolution of continuous improvement methodologies.

1.Plan. Do. Check. Act or PDCA cycle 2.Statistical process control or SPC 3 Quality circles 4 TQM 5.The Baldridge Criteria for Performance Excellence

Which examples demonstrate Poka-yoke characteristics?

A list of steps in a task that must be checked after each step is completed An alarm beeps if a sensor detects that a container of products is too heavy or too light

Which information could you obtain from studying a future state value stream map?

Activities that may be causing waste Process improvement that will remove obstacles to good flow

Which types of information do you get from studying a value stream map?

All the activities involved in creating a product or service Places where waste may be found in a process

What should you consider about your organization before integrating Lean and Six Sigma?

Any constraints around time frame or finances required The nature of the foundational problem you're trying to solve

Label the activities as A required value-adds B waste C value-adds D nonvalue-adds

B- Waste A worker handles a part three times during the assembly process when once would do A- Required value-adds Personnel in the Legal Department prepare and review each supplier contract D- nonvalue-adds A software development process includes a review of each line of code C- value-adds A catering company charges more for its meals if it delivers than if you pick them up yourself

What are some of the benefits of implementing Six Sigma?

Better understanding of key financial drivers within the operations of the organization Improved organizational cultures through inclusion and collaboration Increased customer satisfaction

What are some of the benefits experienced by organization that implement Six sigma?

Better understanding of what customers want and don't want, which leads to customer loyalty Increased market share through reduced costs

Label the characteristics according to whether they apply to Six Sigma Lean Lean and Six Sigma

Both Delivers significant savings Implemented by specialist and teams Use of systematic problem-solving tools Inspired by PDCA Six sigma Uses DMAIC methodology Uses exploratory data analysis Focus on reducing variation Use of statistical tools Lean Uses Kaizen Uses theory of constraints Focus on reducing waste Use of value stream mapping

Suppose your organization is a good fit to implement the Six Sigma methodology. What is the potential value of six sigma to your organization?

By being customer-focused, your levels of customer satisfaction should increase over time. Improve quality in you processes, which will increase net profits over time.

Which questions will help you assess whether an organization is ready for Six Sigma?

Does the organization have a clear vision for the path it wants to take in the future? Will the cost of implementation outweigh the benefits? Are our current improvement approaches and change management structures sufficient? Is change a critical business need now, based on bottom-line, cultural, or competitive needs?

What are some characteristics of six sigma?

It reduces the number of errors in a process by minimizing variation The six sigma metric equals 3.4 defects per million opportunities 99.9997% defect-free Charts process performance against a mean measurement

What are the main stages of deploying Lean Six sigma in an organization?

Make continuous improvements that eliminate waste Look for and identify opportunities for improvement Design a solution that will fix the problems Prioritize the improvement to address first

The Lean methodology is a very effective continuous improvement initiative. What are the key principles of Lean?

Maximize customer value Reduce waste along the entire value stream Improve overall efficiency, quality, and customer satisfaction

Which situations are example of the just-in-time method in use?

Network cable is ordered and delivered to a site only after the installation crew has been scheduled As a worker finishes hand-painting one doll's face, the next doll arrives to be painted.

Match each Lean concept to its description

Pull Create products or service in response to actual customer demand Value Products or features that meet expectations and that the customer is willing to pay for Value stream All the activities in a process lined up to take a product or service from a customer order until the time of delivery Perfection Constant improvement in processes targeting the ideal product or service as require by the customer

What are some of the core concepts that form the foundation of the six sigma DMAIC methology?

Using a cycle of continuous improvement to achieve near-perfection in all processes Using statistics to analyze processes with the goal of sustained improvement Studying input variable to determine which ones have the greatest impact on the output of a process

Which questions should you ask about your organization before intergrating Lean and Six Sigma?

What is our capacity for cultural change? How pervasive are the problems we're trying to fix? The nature of the foundational problem you're trying to solve Any constraints around time frame or finances required.