Improve - Six Sigma Root Cause Analysis and Waste Elimination
A legal consulting firm notices that its employees waste time searching for documents on messy desk and in filing rooms. Hard-copy case files are transported in carts from room to room. In which ways can the firm reduce or eliminate waste?
- Set up teams working in parallel on different aspects of a single case to minimize waiting - Set up a centralized electronic data base accessible to all employees to minimize transportation of paper. - Organize desk and filing systems to reduce excess motion
A six sigma team is investigating why a training session didn't have the desired results. The team decides to create a fishbone diagram to help analyze the problem. Which statements describe effective ways to use this type of diagram.
- The team develops an agreed upon problem statement at the beginning - namely, training efforts have no increased employee knowledge of products - The team brainstorms the casual factors influencing the problem, including lack of time, unprepared instructors and lack of hands on practice. Also called the Ishikawa Diagram, it helps find all the potential causes for one specific effect or problem Causes are generated during a brainstorming session and then grouped by main cause and contributing factors
Which descriptions apply to the kanban pull system for eliminating waste?
Advantage is that business can avoid overproduction by regulating how much material is moving through the process Helps business keep minimal inventory Customer order signals getting processing moving to make parts and materials
An auto manufacturer has incorporated a number of poka-yoke devices into it's manufacturing process. Match each type of poka-yoke to it's example
Checklist: A simple form is used to make sure ach car has been thoroughly cleaned after manufacture Control Methods: Rapid assembly robots shut down if they are not working properly, to avoid rendering defective product Signaling: Workers use screwdriver that check the tightening torque and beep when bolts are over tightened Screening: An industrial lathe is designed so it will not turn on unless the belts are properly tighten
Put the steps in the 5 whys process in the correct order.
Choose a cause and ask why the problem is happening Ask: Why does this occur? List possible causes Investigate potential causes and use data to eliminate some Establish why the remaining cause is happening Determine the actionable root cause of the problem
Which characteristics apply to the kanban-pull method for reducing waste?
For the system to work, material needs to flow at a steady rate in a fixed path It's an inventory control system that indicates when material or stock is needed by a process It helps reduce inventory
An important task for Six Sigma teams is finding the true root causes of problems. Which statement most accurately describes the general process for doing this?
Generate a list of possible causes, group them, and then prioritize the list to determine which ones require immediate attention.
Place the steps of performing a fault tree analysis FTA in the correct order
Identify top event Identify potential causes Identify root causes Prioritize causes Identify countermeasures
To improve processes, six sigma teams must determine the true root causes of problems. Which statement most accurately describes the general process for doing this?
List all possible causes of the problem, group those causes logically, and then prioritize them to determine the vital few that require attention
Workers are regularly searching for tools, navigating around obstructions on the floor and redoing work because equipment settings aren't set right at the plant. By which means can waste be reduced or eliminated?
Organize work space more efficiently ask suppliers to move away from bulk discounting and deliver only needed supplies install equipment poka yoke to limit defects in components and eliminate need for rework
As a six sigma green belt, you must be able to identify different types of waste. Match the types of waste to their examples
Over processing and defects: An overly complex procedure for putting content onto the company's website results in several errors Transportation: Raw materials were moved from the receiving area to the storage room to the factory floor Unnecessary inventory: Excess raw material has to be stored until needed Excessive motion: Employees must walk fairly long distances to fetch various tools and components Overproduction: A factory manufactured 500 switches when only 300 were ordered Waiting: The factory line at a candy manf is held up because a key ingredient has not arrived
The 5s tool can be useful during the improve phase of Six Sigma. What statements accurately describe how to use the 5s tool?
Scrub or clean work area, making corrections and removing trash Straighten or arrange items that are needed Standardize activities for mainlining an organized and clean environment sort through items to determine whats needed maintain or sustain improvements made to reduce waste in the work environment
Match standard work documents to their purposes
Standard worksheets: Visually represent each work sequence Capacity Charts: Chart the output of the machines involved in a process Task and training manuals: used as a reference for procedures, equiptment layouts, safety standards cycle times and quality checks Combination sheets: record manual, walking, automatic, and waiting times in a chart Standard operating sheets: communicate standard timing and procedures and relay accurate up to date info
5s is a practical method for eliminating waste in the workspace. Match each 5s step it's example practice
Standardize: Determine regular inspection methods/routines Scrub: Assign individual responsibilities for cleaning the work space Sort: Inspect and list items that need disposing, donating or relocating Sustain: reward compliant behavior Straighten: Decide at which step in the process each needed item best fits
Match each technique in the 5s approach to its associated practice
Standardize: Record 5s activities and incorporate them into the normal work routine Sustain: Monitor adherence to each of the 5s steps Straighten: Determine the optimum locations for tools, equipment, inventory and supplies Sort: Remove unneeded items from the workspace Scrub: Find sources of dirt and grime and introduce conditions for correction
Which actions are associated with the 5s tool for reducing waste in the work environment?
Straightening or organizing the workspace Standardizing the practices for sorting, straightening, and scrubbing. Sorting out what's needed Sustaining improvements Scrubbing or cleaning the workspace
A workstation team at a manufacture of win turbines is responsible for putting together the arm attachment component. Sequence the four basic steps that the team follows to configure a kanban-pull system
Team determines it will need a 5 day supply of materials in reserve as safety stock Taking mfg and transport time into account the lead time for ordering blades is determined to be 1 week the team calculates it will need to produce a run of 90 units to meet customer demand Team checks calculations and adjust material request
A six sigma team is assessing the activities at a travel agencys call center Match each activity to its type
Value Add: -Book flights/accommodations using online app -Greet customers in friendly way Non value add: -Copies of daily records are stored -move from desk to copier to retrieve documents Required non value add: -Commissions are calculated - insurance forms are filled in per insurers regulations
A six sigma team at a frozen foods factory is assessing the factory's activities and processes. Match examples of activities to their types.
Value add activities: - Slice raw veggies into bite sized pieces -Cook raw veggies in chamber Required non value add: -Calibrate steam chamber to meet food regulation standards - Calibrate slicing machines to cut veggies to desired size Non value add: - Transport to a freezing area -Inspect packing to ensure company logo is displayed correctly
