Process Improvement Tools & Lean & Six Sigma Methodologies Flashcards

What is the main goal of Lean methodology?

Answer: Eliminate waste and add value

The main goal of Lean methodology is to maximize customer value while systematically eliminating waste in all its forms, such as overproduction, waiting, defects, and unnecessary motion. By focusing on value-adding activities and streamlining processes, Lean aims to improve efficiency, quality, and speed. This ultimately leads to a more agile and customer-centric operation.

Which tool is commonly used in Six Sigma to identify root causes of problems?

Answer: Fishbone diagram

A fishbone diagram, also known as an Ishikawa or cause-and-effect diagram, is a visual tool commonly used in Six Sigma to systematically identify the root causes of problems. It helps teams categorize potential causes into major branches like Man, Machine, Material, Method, Measurement, and Environment. This comprehensive approach ensures all possible factors contributing to a problem are considered.

What does DMAIC stand for in Six Sigma?

Answer: Define, Measure, Analyze, Improve, Control

DMAIC stands for Define, Measure, Analyze, Improve, Control, which is a data-driven improvement cycle used in Six Sigma to optimize and stabilize business processes. Each phase systematically guides teams through understanding the problem, collecting data, identifying root causes, implementing solutions, and sustaining the improvements. This structured approach ensures thorough and effective process enhancement.

Which of the following best describes a Kaizen event?

Answer: Short-term improvement workshop

A Kaizen event is best described as a short-term, intensive improvement workshop, typically lasting a few days to a week. During these events, a cross-functional team works collaboratively to analyze and improve a specific process. The goal is to implement immediate changes and achieve tangible results quickly, embodying the principle of continuous improvement.

What does 'value stream mapping' help identify?

Answer: Waste in process flows

Value stream mapping is a Lean management tool used to visualize the entire flow of materials and information required to deliver a product or service to a customer. Its primary purpose is to identify and eliminate non-value-adding activities, or waste, within the process. By streamlining the value stream, organizations can improve efficiency and enhance customer value.

Which tool helps prioritize problems based on frequency?

Answer: Pareto chart

A Pareto chart is a specific type of bar chart that displays the frequency of problems or causes in descending order, along with a cumulative percentage line. This visual tool helps identify the 'vital few' problems that contribute to the majority of issues, allowing for effective prioritization based on their impact or frequency.

What is a 'control chart' used for?

Answer: Monitor process variation

A control chart is a statistical process control (SPC) tool used to monitor a process over time. It helps distinguish between common cause variation (inherent to the process) and special cause variation (unpredictable events), indicating when a process is out of statistical control and requires investigation. This allows for proactive management and improvement of process stability.

Which Lean concept focuses on reducing changeover time?

Answer: SMED

SMED stands for Single-Minute Exchange of Die, a Lean manufacturing methodology focused on drastically reducing the time it takes to complete equipment changeovers or setups. By converting internal setup steps (machine stopped) to external ones (machine running) and simplifying remaining internal steps, SMED aims to increase production flexibility and reduce batch sizes.

Which principle is foundational in Six Sigma?

Answer: Use data to reduce variation

Six Sigma is a data-driven methodology focused on improving processes by identifying and eliminating the causes of defects and minimizing variability. Its core principle is to use statistical analysis and factual data to understand process performance, reduce variation, and move towards near-perfect quality, aiming for no more than 3.4 defects per million opportunities.