Final Exam Review

Question 1

Make-to-Order-Hierarchy

Answer 1

Question 2

Lean is:

Answer 2

• Driving Value (Defined by customer, VOC)
• Make waste visible
• Elimination of waste
• Goal is: Make-to-Order-PULL (MTO-Pull)

Question 3

Six-Sigma is:

Answer 3

• Driving Value (defined by customer, VOC)
• Variation Reduction
• Defect Elimination
• GOAL is: Cost Improvement Initiative

Question 4

Value Stream Mapping

Answer 4

• Defines value and waste
• Map of the current state of the flow of information and materials in a process
• Value
  
  • Value-added activitiies (Improve)
    
    • What the customer is happy/willingto pay for
  • Non-Value added activities (Eliminate)
  • Business-Value added activities (Reduce)
• Waste
  
  • Refer to 8 Wastes
  • Underutilized Talent, Motion, Waiting, Transportation, Over-Production, Over-Processing, Inventory, Defects.
• Flow
  
  • Rapid sequence, sufficient capacity, shortest cycle time.
• Pull
  
  • Work is initiated by kanban, work is limited to value added activities, synchronization, minimal inventory.

Question 5

Value-Added Activities

Answer 5

Time during which value is added in the eyes of the customer.

Question 6

Cycle Time

Answer 6

Time between two products produced by a
certain process step

• Throughput Time
• Machine tact time

Question 7

Throughput

Answer 7

Number of products produced per unit time.

• Throughput rate
• Machine speed-production rate

Question 8

Total Cycle Time

Answer 8

Time product flows from first process until
last process step for given routing

• Process/total throughput time
• Consists of Cycle Time and Changover Time.

Question 9

SIPOC

Answer 9

• Suppliers
• Inputs
• Processes
• Outputs
• Customers

A high-level map used to find areas of improvement.

Question 10

8 Wastes

Answer 10

1. Under-Utilized Talent
2. Motion
3. Waiting
4. Transportation
5. Over-Production
6. Inventory
7. Defects
8. Over-Processing

Question 11

DMAIC

Answer 11

D - Define

M - Measure

A - Analyze

I - Improve

C - Control

Question 12

What is a good approach to sampling?

Answer 12

Random and stratified

Question 13

What is the RTY (Rolled Thoroughput Yield) of 90%, 80%, 70%?

Answer 13

It is the product of all percentages multiplied out:

.9*.8*.7 = 50%

Question 14

What tool is best used to identify all potential critical x’s?

Answer 14

A Process Map

Question 15

Which flowchart technique highlights processes w/ people?

Answer 15

Activity Flow Map

Question 16

The Kano model shows?

Answer 16

Relationships between “must haves” and delighters

Question 17

An Affinity diagram allows you to?

Answer 17

Categorize and group like things together.

Question 18

When sampling, precision is a measure of?

Answer 18

How much of a difference makes a difference

Question 19

Y in the statement Y=f(x1,x2,x3…) means?

Answer 19

Process output

Question 20

Design of Experiments (DOE) is used to?

Answer 20

DOE is used to prove causation.

Question 21

What is mistake proofing and why do it?

Answer 21

Known as Poka-yoke, it is used for the elimination of error.

Question 22

What should you use to select a solution?

Answer 22

Solution Priortization Matrix

Question 23

Name 2 reasons to pilot a solution:

Answer 23

1. Prove or validate the expected results
2. Better understand the risks
3. Facilitates the buy-in for smoother implementation.

Question 24

Name the 3 rating elements used in FEMA. Which one usually doesn’t change when you reduce overall risk?

Answer 24

Severity, Occurrence, Detection. Severity usually never changes, it’s typically the same impact as before the change took place.

Question 25

Project Charter contains:

Answer 25

Scope, Objective, Business Case

Question 26

What is Change Management?

Answer 26

Getting individuals and groups READY, WILLING, and ABLE to implement new processes.

Question 27

What is the main focus of a change-management plan?

Answer 27

People Factor

Question 28

What is RTY of a three step process, all having 95%?

Answer 28

.95\*3/3 = 95%

Question 29

What are the types of variation?

Answer 29

Common and Special causes Common - historical or expected cause Special - an outlier or unexpected event

Question 30

Name 3 reasons why batch processing should be avoided?

Answer 30

1. Creates WIP 2. Increases opportunity for damage 3. Increases inventory carry costs 4. It is a ridged process that accomodates the batch size only.

Question 31

Name 2 reasons a 'good' change fails?

Answer 31

1. Poor communication 2. Lack of tangible results 3. Everything is a high priority 4. VOC is not heard

Question 32

What are the 3 critical factors in preparing an organization for change?

Answer 32

1. Planning 2. Communication 3. Organization 4. Buy-In

Question 33

What does PDCA stand for? Why do it?

Answer 33

Plan, Do, Check, Act. Use it when developing or implementing a new process. PDCA Cycle for Standardization

Question 34

What flowchart best highlight handoffs between processes and functions?

Answer 34

Activity Flowchart or Swim Lane flowchart. Go here, then here, then to sales, etc....

Question 35

Describe a process that is performing at Six Sigma:

Answer 35

3.4 defects per million opportunity The closest specification limit is no closer than six standard deviations away.

Question 36

What is the name of the document that describes in detail how to execute a process or step? Who MUST be involved in it's creation?

Answer 36

SOP - Standard Operating Procedures The one responsible for executing the process (machine operator) MUST be included in it's creation.

Question 37

To assure that a process will achieve an expected result, it is important to monitor what?

Answer 37

The critical x's (in-process variables) that were proven to be cause and effect.

Question 38

What visual process/tool determines if a process is in control or not?

Answer 38

Control Chart

Question 39

Name 3 costs of failed change?

Answer 39

1. Wasted resources 2. Business objectives are not met 3. Moral suffers 4. Long-term strategies are not achieved

Question 40

What does the 5's stand for?

Answer 40

1. Sort 2. Shine 3. Standardize 4. Sustain 5. Stabilize

Question 41

What can be achieved by applying the tools, methods, and the start of six-sigma?

Answer 41

In the quest for Make-To-Order you reduce the Supply Chain cost by removing waste and variation, inherently improving quality, and customer satisfaction.

Question 42

What is a FMEA?

Answer 42

Failure, Mode, Effect, Analysis. * Structured approach to identify, estimate, prioritize and evaluate risk. * Aims at failure prevention * Primarily used to limit the risk involved in changing the process.