Summary Lean Six Sigma & Minitab The Complete Toolbox Guide for All Lean Six Sigma Practitioners

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ISBN-10 0954681363 ISBN-13 9780954681364
218 Flashcards & Notes
3 Students
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This is the summary of the book "Lean Six Sigma & Minitab The Complete Toolbox Guide for All Lean Six Sigma Practitioners". The author(s) of the book is/are Quentin Brook. The ISBN of the book is 9780954681364 or 0954681363. This summary is written by students who study efficient with the Study Tool of Study Smart With Chris.

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Summary - Lean Six Sigma & Minitab The Complete Toolbox Guide for All Lean Six Sigma Practitioners

  • 0 Random stuff

  • What is Six Sigma? Name a few descriptions or definitions.
    Data driven problem solving
    Quality level 3.4 rejects per million
    Life changing philosophy
  • What does DMAIC stand for?
    Define
    Measure
    Analyse
    Improve
    Control
  • What happens in the Define Phase?
    Develop a clear project charter based on a real problem that is relevant to the customer
    Will provide significant benefits to the business
  • What happens in the Measure Phase?
    To understand and baseline the current performance of the process
    This happens through a set of relevant and robust measures (KPI)
  • What happens in the Analyse Phase?
    To find the root causes of the problem and understand/quantify their effect on process performance
  • What happens in the Improve Phase?
    To develop, select and implement the best solutions with controlled risks.
  • What happens in the Control Phase?
    To ensure the solutions are embedded the process has robust controls and the project has clear closure.
  • Why is there a decision point in the Define phase?
    Project is reviewed to assess the Define phase outputs, to see if the project is worth doing, and to commit to resources required to succeed.
  • What is a LEAN process?
    A LEAN process is one that delivers products or services that the customer wants, at a price that reflects only the value the customer is willing the pay for.
  • What does a customer want in LEAN?
    Needs to be fast
    Needs to be flexible
  • What do customers not want to pay for? (what happens anyway)
    Making to many products before they are needed
    Throwing away or fixing faulty product or services
    Delays or unclear communication in the process
    Wasted energy during the provision of products and services

    These costs are also called wastes
  • Name two important persons in LEAN
    J. Womack 
    D. Jones
  • Name the LEAN tools in the Define Phase
    Define value (time value maps)
    House of quality
  • Name the tools in the Measure Phase
    Lean measures, like:
    Process Cycle Efficiency (PCE)
    Overall Equipment Effectiveness (OEE)
    Lead time
    Takt time
  • Name the tools in Analyse Phase
    Value stream mapping
    Time value maps
    Value add charts
    Spagetti diagrams
  • What tools are can be found in Improve and Control phases?
    Single Minute Exchange of Dies (SMED)
    Kanban
    One Piece Flow
    5S
    Error Proofing (Poka Yoke)
    Standardized processes
    Visual Management
  • What is most important in Lean what covers Define, Measure and Analyse phase?
    Identifying waste or one of the 7 wastes.
  • 1 Define Phase

  • What makes a good Problem Statement?
    Keep it short
    Avoid technical language
    Quantify the problem
    Explain the cost of the problem
    Define the scope of the project

    SMART is a good checklist
  • What is/are Costs of Poor Quality?
    it refers to all costs related to the problem
  • Give examples of COPQ
    Rework
    Rejects
    inspection
    testing
    customer returns
    complaints
    Excess inventory
    Late payments
    expediting costs
    high employee turnover
  • What are hard and soft benefits with COPQ?
    Hard benefits are measured as financial gains
    Soft benefits are measured as non-financial gains
  • What are the methods to discover VOC?
    Customer complaints; easy to start but beware of bias
    Direct contact; phone calls, focus groups, interviews
    Less direct methods; surveys. feedback cards, market research, competitor analysis
    Become a customer of your own organization
  • What is Kano Analysis?
    Kano is a framework for categorizing and prioritising the different performance features of a product or service.

    Kana has three categories:
    Must haves, critical to have on a product or service. If it is not there count as dissatisfiers
    More is better, performance requirement
    Delighters, features that provide wow factor
  • What is House of Quality?
    Helps correlate customer requirements with products or service so that only real value is delivered.

    Begins with customer needs (whats)
    Translate customer needs to products or service (hows)
    Assess the link between the whats and the hows
    Now specific requirements can be fulfilled in production
  • What is Quality Function Deployment? (QFD)
    QFD refers to an overall approach for understanding the needs of the customer next to House of Quality.
  •  What is Critical to Quality Tree?
    Used to present the results of VOC, it provides clarity and structure for developing quantifiable specifications

    So how does it work?
    Define the specific event
    Identify broad customer requirements
    Break down broad requirements into specific CTQ.
    Develop CTQ specifications
  • What is SIPOC?
    Suppliers, Inputs, Process, Outputs, Customers
    Its a simple process map, it helps clarify the core process the project is focussed on.
  • What is a Gemba walk?
    Actually go and see the process.
  • What are the key steps in Gemba?
    Use a cross functional team
    Go and see
    Observe and touch
    Ask open questions
    Avoid assumptive questions
  • What is a project plan?
    An overview containing all those involved in the project.
  • What is a Six Sigma champion?
    Ensures that the project fits within Lean Six Sigma
  • What is a Project Sponsor?
    Responsible for the project
  • What is a Project Leader?
    Black belt, who leads the project day to day
  • What are Team members?
    Green belts
  • What is Stakeholder Analysis?
    Mapping people that will be involved or affected by the project, or people who have some control over the project or process. This is done on basis of Power and Position.
  • What is a Project Charter?
    Used to summarize the findings in de Define Phase.
  • What is in a Project Charter?
    Project title
    Team structure
    Problem and Goal statement
    COPQ
    VOC
    Scope
    Stakeholders
    Project Plan
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Latest added flashcards

What is 5S?
Sort (Seiri): Get rid of the clutter. Clean the workplace
Straighten (Seiton): Find everything a place
Shine (Seiso): Keep everything clean and tidy
Standardise (Seiketsu): Develop a system
Sustain (Shitsuke): Keep it going!
What are the benefits of One Piece Flow?
Reduced response lead times and higher on time delivery
Increased flexibility and productivity
Lower inventory (Work in Progess) and associated storage space
Improved quality
What is One Piece Flow?
It is a system where products or services are processed indiviually and flow between process steps without waiting.
What types of Kanban are there?
There are two types. Withdrawal Kanban and Production Kanban
What does Kanban help create?
Moving from a push system to a pull system.
What is a Kanban?
Kanban is a card which accompanies inventory within a production cycle. Kanban controls the level and flow of inventory, creating a more steady system.
What are the four key areas of TPM?
Preventive maintenance
Breakdown Maintenance
Corrective maintenance
Maintenance prevention
What is Total Productive Maintenance?
TMP is an proactive approach to maintenance that aims to eliminate unplanned downtime and maximize equipment effectiveness. 
Key element is that all workers are responsible for continuous maintenance, creating prevention instead of reaction.
What are the benefits of SMED?
Flexibility
Quicker Delivery
Better quality
Higher Productivity
What is Single Minute Exchange of Dies?
It is an approach that reduces set up times.