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Lean Six Sigma Midterm Questions and Answers Fully Solved
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Lean Six Sigma Midterm
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Lean Six Sigma MidtermWhat is Sigma and Six Sigma? - answer Sigma - 18th Letter of Greek Alphabet
Six Sigma - Business Philosophy focusing on continuous improvement
- mindset
- organized process for structured analysis of data
- 3.4 PPM - 3.4 defects per million - measure of variability representing optimum level of
quality for an organization
Six Sigma Characteristics - answer-Deployment of statistical tools to eliminate or reduce
variation, defects and waste from business process & result in better financial results
- NOT theoretical exercise, NOT a quality program (though based on TQM)
WHY Six Sigma? - answer- Provides BREAKTHROUGH improvement in customer
satisfaction & shareholder value
- proven methodology to solve problems
- focus on the bottom line
WHEN to use Six Sigma? - answer- Unknown causes or situations
- Complex situation with many variables
- Problems are commonplace & not well defined
Six Sigma Belts - answer Yellow Belt - knows basic analytical tools & assist GB in
projects
Green Belt - knows basic analytical tools & delivers focused projects
Black Belt - leader of team and lays emphasis on application & analysis
Master Black Belt - trainer of BB, coach of projects, leads project reviews, understands
adv. statistical theory
DMAIC - answerDEFINE - the project, goal, deliverables to customers
MEASURE - current performance of project
ANALYZE - determine root cause(s) of defect
IMPROVE - process to eliminate defect
CONTROL - performance of project
Steps to Implement Six Sigma - answer- Identify opportunities
- Define the project & write charter
- Build team
- Measure & Document 'As-Is' process
- Analyze & identify waste
- Optimize the flow & plan new process
- Implement & validate the new process
, - Review & Re-run the new process
- Document & Communicate the success
Walter Shewart - answer- Father of statistical quality control
- Brought together disciplines of statistics, engineering & economics
W. Edwards Deming - answerDeming Cycle - PDSA
- Plan, Do, Study (Check), Act
Joseph M. Juran - answerJuran trilogy - Quality Planning, Control, Improvement
Armand Feigenbaum - Historian - answerOriginated concept of Total Quality Control
and wrote book of same name
3 steps - Quality Leadership, Modern Quality Technology, Organizational Commitment
Philip B. Crosby - Historian - answerAuthor of 'Quality is Free' 'Quality without Tears'
'Let's Talk Quality'
- "Zero defects" concept
Kaoru Ishikawa - Historian - answerDeveloped cause and effect diagram
Genichi Taguchi - Historian - answerFractional factorial designed experiments &
stressed the concept of robustness
What is Lean? - answerProducing maximum sellable products or services at lowest
operational cost while optimizing inventory levels
Background of Lean - history - answerHenry Ford's Model T automobile
Toyota's continuous improvement post-WWII
Value - answer- Defined by customer
- Japanese cars: reliable, quality, resale value, fuel efficiency, etc.
- German cars: some of above along with PRIDE of ownership
- Watches: Japanese vs. Swiss
Value Stream - answer- Series of activities required to deliver product or service
3 components:
- Flow of materials (movement of raw materials)
- Transformation of raw materials into finished goods (Input to Output)
- Flow of information required to support flow of materials (POs, work orders, etc)
Types of Activities in a Process - answerValue Added
Business Value Added
Non-Value Added
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