6 Sigma

The Six Sigma problem solving strategy all begins with a simple equation:

y = f(x)

This stage reviews the metrics, and using a variety of tools, gains an understanding of the cause and effects interactivity within the system being looked at.

Analyze

"Quality" is not about products being accurate as you see it, but rather:

As the customer sees it

Regular ______________ is vital throughout the six sigma project

Communication

Six Sigma reduces costs and waste by determining the:

Cost of Poor Quality

The ___________ is the sum of internal and external failures.

Cost of Poor Quality (COPQ)

Sometimes a need arises where no existing process for undertaking an activity or achieving a customer-needed output exists. In this case you would use _______ instead of DMAIC.

DMADV (Define, Measure, Analyze, Design and Verify)

Every Six Sigma project will follow the same process in a systematic and uniform method known as:

DMAIC

Sigma levels determine the rate of defects and are a standardized measure of the error rate of a process, based on the:

Defects per Million Opportunities (DPMO) estimate

The purpose of the _______ Stage of DMAIC is to define the problem, agree on the goals, and listen to the voice of the customer.

Define

DMAIC stands for:

Define, Measure, Analyze, Improve, Control

Six Sigma is an improvement methodology which uses the following phases to make changes to any process:

Defining, Measuring, Analyzing, Improving, and Controlling. (DMAIC)

Theory of Psychology

Explains how to understand people, interactions between people, and interactions between leaders and employees in a system of management.

A systematized technique which identifies and ranks the potential failure modes of a design or manufacturing process in order to prioritize improvement actions.

Failure Mode and Effects Analysis (FMEA)

Allows you to evaluate if a project or proposed process improvement calculation is statistically significant, or if the same thing could have occurred by random chance.

Hypothesis testing

Describes the provision of items in the production process only at the exact point they are needed.

Just-in-Time (JiT)

A workshop or event to identify waste areas or functions.

Kaizen

Theory of Knowledge

Knowledge is not possible without theory, and experience does not establish a theory by itself. *Copying a best practice without understanding the theory behind it could be devastating for an organization.

Theory of Optimization

Optimization of the total system, not just individual

A ________ is a series of tasks that is repeated time and again. It has a set order to it, and the people who do it on a daily basis are best placed to tell you about it.

Process

Used to determine whether a process is capable of consistently achieving the required specifications.

Process Capability Study

Manager or member of the operational team that currently has responsibility for the part of the business about to be improved.

Process Owner

This is the single individual or group with responsibility for the end-to-end process.

Process Owner

The goal of Six Sigma is improved:

Process performance and increased customer satisfaction *through variability and defect reduction, resulting in consistently producing high quality services, products, or processes.

The key project information is defined in the:

Project Charter

Formal document used to summarize key deliverables and information for a Six Sigma project.

Project charter

Six Sigma team formation typically consists of:

Stakeholders, executives, champions, and team members (yellow belts) who are led by a green belt or black belt.

Used to monitor processes and may be applied to production or business processes. Uses statistical methods to ensure that the process is stable and monitor the processes for timely identification of special causes.

Statistical Process Control

PDCA and PDSA are:

cyclic processes for planning and testing improvement activities prior to full-scale implementation

Six Sigma requires a buy-in across the business for the project to:

make changes based upon the measurements of an improvement plan project, irrespective of personal views **Guesswork and assumptions have no place; it is a precise process.

• Deming's theories were taught as a part of his System of Profound Knowledge. His knowledge system consists of four interrelated parts:

(1) Theory of Optimization (2) Theory of Variation (3) Theory of Knowledge (4) Theory of Psychology

The steps in the Deming PDCA or PDSA Cycle are:

1. (P) Plan a change or test it. 2. (D) Do it by carrying out the change or test on a small scale. 3. (C) Check it by observing the effects of the change or test. 4. (S) Study it by reviewing what you have done or changed. 5. (A) Act on what you have learned. 6. Repeat and continuously evaluate the process.

"Six Sigma" measures the capability of a process to perform defect-free work with a failure rate of:

3.4 parts per million (or 99.9997%)

At the 2nd Sigma level, ____ defective parts per million occur

308,538

Six Sigma designates clear roles for people within the project using:

Colored Belts

_____ refers to a difference from the expected or likely outcome.

Variation

Muda is the word for:

Waste

Reducing poor quality is accomplished by:

- Understanding who your customers are and what is important to them - Understanding customer feedback, called the Voice of the Customer, and determining the necessary requirements for your product - Prioritizing issues related to your product - Determining internal processes and what causes variation - Determining what causes defects - Developing ways to address the defects - Developing metrics to standardize and measure the changes made in the process

The deliverables of the Analysis phase include:

-A root cause analysis for concerns -Gap analysis -Top-to-bottom data and process analysis

The deliverables for the Define phase include:

-Developing a fully-trained project team who is committed to the improvement and has the full support of management, including necessary resources. -Identifying what characteristics are Critical to Quality for the customer -Developing a project charter -Mapping the known business processes.

The deliverables for the Improve phase include:

-Developing possible solutions -Determining which ones are the best solutions -Developing a subsequent implementation plan.

The deliverables of the Measure phase include:

-Identifying key measures -Developing and deploying a data collection plan -Developing a baseline for performance -Documenting variation -Communicating it to team members and stakeholders.

The core activity in examining any Lean process is to: (3 items)

-Map out the current components -Identify which elements are waste -Change or improve those wasteful elements and construct a new or improved process that is leaner

Six Sigma focuses on:

-Reducing defects -Preventing rework -Eliminating waste in processes which produce a customer's product

Lean is based upon 2 key principles:

-Removal of irregularity -Removal of irrelevance

The deliverables for the Control phase include:

-Standardizing processes -Documenting procedures -Implementing the monitoring plan -Transferring ownership of the project and closing the project

At the 5th Sigma level, ____ defective parts per million occur

233

The Seven Elements of Waste are:

-Transport -Inventory -Motion, -Waiting -Over Producing -Over Processing -Defects (See Slides 18-20 [Part 4])

Lean enterprise eliminates:

-Waste -Non value-added activities

A Lean tool that allows examination of a process to identify non value-added elements

5S Tool

At the 4th Sigma level, ____ defective parts per million occur

6,210

At the 3rd Sigma level, ____ defective parts per million occur

66,807

At the 1st Sigma level, ____ defective parts per million occur

690,000

In statistics, ________ is a measure that is used to quantify the amount of variation or dispersion of a set of data values.

Sigma

Who first introduced the Six Sigma methodology?

Bill Smith

The success of Six Sigma and Lean is based on:

Building a culture of support

One of the key requirements for introducing any Six Sigma change is gaining:

Buy-in of the business and the people impacted

Name this diagram: ->->->

Cause and Effect Diagram (Fishbone)

The person who sponsors the Six Sigma project

Champion

Introducing a Six Sigma process change overlaps with a considerable amount of

Change Management

Systematic series of tests used to determine relationships of x and y variables that affect a process and response.

Design of Experiments

Lean Methodology works on the basis of improving quality by:

Eliminating waste

This uses the information found in your analysis and develops possible solutions.

Improve

Theory of Variation

Improving product and service uncertainty and variability in design and manufacturing process.

This stage of DMAIC is where the starting point metrics are recorded to baseline the current performance level and constraints of the process to be worked upon.

Measure

Designed to improve the process when the apparent variation is caused by variations in the measuring system.

Measurement Systems Analysis (MSA)

The center point of a range of values. For a data set, it may be thought of as the "middle" value.

Median Average

Poka-Yoke means:

Mistake Proofing

In Lean, _____ is unevenness in work demand or work flow

Mura

_______ refers to overburdening or placing too much upon one thing.

Muri

What is this an example of? _________________/\________________ (4) (3) (2) (1) 0 1 2 3 4 5

Normal distribution graph, where 0 is the mean average point

(PDCA) Cycle stands for:

Plan , Do, Check, Act

Kaizen uses the ___________________ cycle as a Lean operating model.

Plan-Do-Check-Act (PDCA)

The Deming Cycle is also known as the:

Plan-Do-Check-Act (PDCA) Cycle ~or~ Plan-Do-Study-Act (PDSA) Cycle

ISO 9000

Quality Management Standards

ISO 9001

Quality Management System Standards

___________ is a sampling from a population in which the selection of a sample unit is based on chance. Every element of the population has a known, non-zero probability of being selected.

Random Sampling

Used to determine the strength of a relationship between data output and input.

Regression analysis

Bias that results from problems in the measurement process. Bias due to measurement error can occur with a poor measurement process.

Response bias

______ is the probability that a product will pass through the entire production or service process without rework and defects.

Rolled Throughput Yield (RTY)

The _______ helps team members determine process activities, stakeholders, and boundaries. It shows the Suppliers, Inputs, Process, Outputs, and Customers of a process.

SIPOC

Name this diagram: o<~~~>\ o<~>v<~~~>o

Spaghetti Diagram

How can you collect data to determine the needs of the customer and the Voice of the Customer?

Surveys, interviews, in person, focus groups, email, or phone

Could possibly be the most important part of the entire DMAIC methodology. Helps verify that the Voice of the Customer is being met by verifying improvement processes, documenting procedures, and updating standard operating procedures and policies.

The control plan

For y = f(x), the Y represents:

The desired outcome, result, or goal you want to achieve.

When a company undertakes a Six Sigma project they must start by investing in:

Their employees (Training & Awareness)

"The objective of an organization is the optimization of the total system and not the optimization of individual subsystems."

Theory of optimization

This bias occurs when some members of the population are inadequately represented in a sample.

Under-coverage bias

Defining the _________ includes what the customers' requirements are for product and what their expectations are: both positive and negative

Voice of the Customer (VOC)

The term _________ is used in Six Sigma as a descriptor of the necessary factors that contribute to the value of a product or service from the viewpoint of the customer.

Value Stream

This describes the activities that provide the customer with value in delivering their product.

Value Stream

A graphical representation of all the elements that make up a process or production.

Value Stream Map (VSM)

Business success depends on:

improving business process and results in combination with great customer service

Dr. W. Edwards Deming (1900-1993) is best known for:

reminding management that most problems are systemic and that it is their (management's) responsibility to improve the systems so that workers can do their jobs more effectively.

By using _____________________, organizations can discover internal problems that may or may not be apparent.

research and data collection