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Process improvement, six-sigma, lean six sigma Questions with Solutions
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Process improvement, six-sigma, lean six sigma
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Process improvement, six-sigma, leansix sigma
Breakthrough - answerthe accomplishment of any improvement that takes an
organization to unprecedented levels of performance
What breakthrough attacks - answerchronic losses common causes of variation
what provide foundations for breakthrough - answerprocess improvement
methodologies and six sigma approaches
Statistical thinking - answerphilosophy of learning and action based on these principles:
-All work occurs in a system of interconnected processes
-Variation exists in all processes
-Understanding and reducing variation are the keys to success
Sources of variation in a production process - answerInputs: materials and tools
Process: operators, methods, machines, environment, measure instruments
Outputs: Human inspection perform
Problems created by variability - answerunpredictability
reduce capacity of utilization
contributes to the Bullwhip effect.
difficult to find root of causes.
difficult to detect problems early.
Types of variation - answer-Uncontrollable variation (common causes) are a natural part
of a process
-Special (assignable) causes of variation can be recognized and controlled
-Failure to understand these differences can increase variation in a system
Process improvement methodologies - answer•Redefining and analyzing the problem
•Generating ideas: "Brainstorm" to develop potential solutions.
•Evaluating and selecting ideas
•Implementing ideas
Deming cycle 'Deming wheel' - answerImplementation of PDCA
1. Design the product with appropriate tests.
2. Make the product and test in the production line and in the laboratory.
3. Sell the product.
, 4. Test the product in service and through market research
PDSA (plan-do-study-act) - answerimprovement comes from the application of
knowledge. This knowledge of engineering, management, or how a process operates
that can make a job easier, more accurate, faster, less costly, safer, or better meet
customer needs.
Basic framework for developing, testing, and implementing changes to any process that
will lead to improvement.
fundamental questions for PDSA - answer•What are we trying to accomplish?
•What changes can we make that will result in improvement?
•How will we know that a change is an improvement?
Creative Problem Solving - answer•soikufu-creative thinking or incentive ideas, which
means capitalizing on worker's suggestions.
Creative problem solving (CPS) process - answer•Understanding the "Mess"- identify
symptoms
•Finding Facts - gather data; operational definitions
•Identifying Specific Problems - find the root cause
•Generating Ideas - brainstorming
•Developing Solutions - evaluate ideas and proposals
•Implementing Solutions - make the solution work
Cutom improvement methodologies - answerFADE (Focus, Analize, Develop and
Execute)
DRIVE (Define the problem, Recognize the cause, Identify the solution, Verify the
actions, Evaluate the results) - Lexus
DMAIC six-sigma - answerDefine
Measure
Analyze
Improve
Control
Six-sigma - answerBusiness improvement approach that seeks to find and eliminate
causes of defects and errors in manufacturing and service processes by focusing on
outputs that are critical to customers and a clear financial return for the organization.
Term six-sigma - answerbased on a statistical measure that equates to 3.4 or fewer
errors or defects per million opportunities (dpmo)
Six-sigma (Motorola 1980) - answerThere is only one ultimate goal: zero defects—in
everything we do.
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