Improve Phase

Question 1

What is the improve phase?

Answer 1

What are the solutions for eliminating the root causes

Question 2

What are the 5 different solution approaches/stages?

Answer 2

Quick hits
Good practice
Simulation
Looking at current approaches
Refine creativity techniques

Question 3

What are the 4 lean approaches in the improve phase?

Answer 3

Defects
Constraints
Inventory
Complexity

Question 4

What is used as a lean approach for defects and make it error free?

Answer 4

Poka Yoke

Question 5

What is used as a lean approach for constraints?

Answer 5

Reduction and theory of constraint

Question 6

What is used as a lean approach for inventory?

Answer 6

Pull systems

Question 7

What is used as a lean approach for complexity?

Answer 7

Process maps

Question 8

What is the purpose of the 5 S’s

Answer 8

To create a clean, structured and highly efficient workplace

Question 9

What are the 5 S’s?

Answer 9

Sort
Set in order
Shine
Standardized
Sustain

Question 10

What does it mean to sort?

Answer 10

Remove what you do not need

Question 11

What does it mean to set in order?

Answer 11

To bring in things to a useful order

Question 12

What does it mean to shine?

Answer 12

Clean up and maintain

Question 13

What does it mean to standardize?

Answer 13

Implement standard SOP’s

Question 14

What does it mean to sustain?

Answer 14

Build up routines and responsibilities

Question 15

What is Poka Yoke?

Answer 15

To make unintentional mistakes impossible and error proof

Question 16

What are the two types of Poka Yoke?

Answer 16

Preventive
Reactive

Question 17

What is SMED stand for?

Answer 17

Single minute exchange of die

Question 18

What is the process for SMED?

Answer 18

Document the process
Transform internal into external activities
Optimize internal activities
Optimize adjusting

Question 19

What is a push system?

Answer 19

A production line that pushes the product forward to demand

Question 20

What is a pull system?

Answer 20

Production based off of the customer dictating the need

Question 21

What is the theory of constraints? 5 things

Answer 21

Identify the constraint
Exploit the constraint
Align to the constraint
Elevate the constraint
Find the next constraint
Repeat

Question 22

What are the two types of brainstorming?

Answer 22

Verbal and nonverbal, open or closed

Question 23

What is brain writing?

Answer 23

Combination of open and closed brainstorming that is passed on a document among the team members and repeated

Question 24

What is an anti-solution brainstorm?

Answer 24

How can we make things worse?

Question 25

Who should be used in an anti-solution brainstorming session?

Answer 25

Critical members

Question 26

What is an analogy brainstorm?

Answer 26

Relating the problem to people, colors, nature, competitors, etc.

Question 27

What is the first step in the filter solutions process?

Answer 27

Sort out the impossible solutions

Question 28

What are some examples of impossible solutions?

Answer 28

Legal or physical laws Ethics or morality Contracts Business directives Project Customer requirements

Question 29

What is the second step of the filter solutions?

Answer 29

Sort out unfeasible solutions

Question 30

How do you determine what is an unfeasible solution?

Answer 30

Define what effort and benefit is and how you scale it in a high medium low matrix

Question 31

If applicable, how do you narrow down your solution pool even more after the effort benefit matrix?

Answer 31

N/3-number of votes for each team member Normal grouping technique N= number of ideas or solutions Normal grouping technique -define the scale and discuss outliers

Question 32

What does To-Be mean in finalizing solutions?

Answer 32

What do I need to add to make it ideal?

Question 33

What 2 details are needed to complete a To-Be, finalized solution?

Answer 33

Define or clarify functions for the process Build up the process according to the functions

Question 34

What are the 6 categories of the To-Be process?

Answer 34

Functions – who does what? Form – centralized system, process, layout Definition – specify overall solution, and create process SOP (Lean, RACI, complexity) Visualization – map the new process together with stakeholders from the process Review – assess risk (risk, matrix, FMEA) Communication – transfer results, get feedback and acceptance from stakeholders

Question 35

What does FMEA stand for?

Answer 35

Failure mode effect analysis

Question 36

What does FMEA do?

Answer 36

Looking for potential failures in the process steps

Question 37

What is RPN?

Answer 37

Risk priority number

Question 38

How do you calculate the RPN?

Answer 38

S x O x D S= severity O= occurrence D = detection probability

Question 39

How do you mathematically measure success?

Answer 39

Success = quality x acceptance

Question 40

What is tool 4?

Answer 40

Cause solution matrix

Question 41

What is the purpose for tool 4?

Answer 41

Do I have a solution for every root cause? Are the solutions conflict free?

Question 42

What does PDCA stand for?

Answer 42

Plan Do Check Act

Question 43

What is the first step in implementing solutions?

Answer 43

Coming up with a plan that contains: Responsibilities Time Budget Risk Communication

Question 44

What is the purpose of the KPI charter?

Answer 44

To actively steer the KPI’s in focus and react to deviations as early as possible

Question 45

What is all included in your KPI charter? 7 things

Answer 45

KPI Operational definition Specification limit Sampling Responsibilities Sponsor and process owner Control charts

Question 46

What are the 4 goals of the gate review for the improve phase?

Answer 46

Generate solutions Refine and filter solutions Finalize solutions Implement solutions