OM Process Optimization 3 — Questions and Answers
Question 1: What is the goal of 'Design for Six Sigma' (DFSS) compared to traditional Six Sigma?
- To fix existing defects faster
- To build quality and performance into new products or processes from the start (Correct answer)
- To reduce the number of DMAIC cycles needed
- To eliminate the Control phase requirements
Correct answer: To build quality and performance into new products or processes from the start
DFSS proactively designs new products and processes to meet Six Sigma quality levels rather than correcting defects after the fact.
Question 2: A manager wants to reduce changeover time between production runs. Which technique is specifically designed to accomplish this?
- Poka-yoke
- SMED (Single-Minute Exchange of Die) (Correct answer)
- 5S methodology
- Value stream mapping
Correct answer: SMED (Single-Minute Exchange of Die)
SMED is a Lean technique focused on reducing equipment changeover or setup time to less than ten minutes to increase flexibility and reduce batch sizes.
Question 3: In process optimization, 'muda' refers to which of the following?
- Variation in process outputs
- Any activity that does not add value (waste) (Correct answer)
- Overburdening of workers or equipment
- Unevenness in production flow
Correct answer: Any activity that does not add value (waste)
Muda is the Japanese term for waste — any activity that consumes resources without adding value for the customer.
Question 4: Which type of process map shows the flow of work across multiple departments or functional areas?
- Flowchart
- Swim-lane diagram (Correct answer)
- Value stream map
- SIPOC diagram
Correct answer: Swim-lane diagram
A swim-lane diagram divides a process map into horizontal or vertical lanes, each representing a department or role, to show handoffs and responsibilities.
Question 5: What does 'Overall Equipment Effectiveness' (OEE) measure?
- Total cost of equipment ownership
- The combined impact of availability, performance, and quality on equipment productivity (Correct answer)
- The ratio of planned to unplanned downtime
- How often equipment meets its maintenance schedule
Correct answer: The combined impact of availability, performance, and quality on equipment productivity
OEE is calculated as Availability × Performance × Quality, providing a single metric that reflects how effectively manufacturing equipment is being used.
Question 6: An organization wants to prioritize which process improvements will have the greatest impact. Which tool should they use?
- Gantt chart
- Impact-effort matrix (prioritization matrix) (Correct answer)
- Control chart
- Process capability index
Correct answer: Impact-effort matrix (prioritization matrix)
An impact-effort matrix plots potential improvements by their expected benefit versus the effort required, helping teams focus on high-impact, lower-effort changes first.
Question 7: In the context of DMAIC, what is the primary objective of the 'Analyze' phase?
- Collect baseline process performance data
- Identify and verify the root causes of the problem (Correct answer)
- Implement solutions and test them
- Monitor the improved process over time
Correct answer: Identify and verify the root causes of the problem
The Analyze phase uses data and statistical tools to identify, prioritize, and validate the root causes driving the gap between current and desired performance.
OM Process Optimization 3
What is the goal of 'Design for Six Sigma' (DFSS) compared to traditional Six Sigma?