Introduction

Question 1

Paths to cost reduction

Answer 1

-cut services
-reduce labor (layoff)
-contract work out
-eliminate product features
-remove roadblocks so your employees can produce
-assign resources to bottlenecks
maximize internal capabilities
focus on what the customer wants to buy

Question 2

combines ideologies that aims to reduce or eliminate wastes and variations among processes in an organization

Answer 2

Lean
Six Sigma

Question 3

Problem Solving tools

Answer 3

-kanban
-kaizen
-spc
-JIT-pull
-Visual Mgt
-5S
-Setup Reduction
-Value Stream Mapping
-Hypothesis testing
-anova
-doe
-dfss
-root cause analysis

Question 4

Focus on what is to VALUE to customer

Answer 4

Lean

Question 5

Maps the actions required to produce

Answer 5

Value Stream Mapping

Question 6

Separate the non-value added with the value added

Answer 6

Lean

Question 7

Produce only what the customer needs

Answer 7

Pull system

Question 8

more to value than just costs

Answer 8

Value

Question 9

“defined by the ultimate customer”

-womack

Answer 9

Value

Question 10

what does VOC means?

Answer 10

Voice of the Customer

Question 11

value is expressed in terms of …

Answer 11

specific product or function or capability

Question 12

“what does the customer wants to buy?”

Answer 12

Value

Question 13

“What would they pay extra for?”

Answer 13

Value

Question 14

types of activities

Answer 14

Value added
Non-Value added

Question 15

brings product closer to its final form

Answer 15

Value added

Question 16

changes the form, fit, function

Answer 16

Value added

Question 17

an activity that a customer is willing to pay for

Answer 17

Value added

Question 18

does not contribute to bringing the products into final form

Answer 18

Non-Value Added

Question 19

doesn’t improve the form,fit, function of the product or service on the first pass

Answer 19

non value added

Question 20

an activity a customer is not willing to pay for

Answer 20

non- value added

Question 21

waste

Answer 21

non-value added

Question 22

improve value added work steps, better tools, machines, instruction, redult: small timesavings

Answer 22

Traditional Focus of Lean Approach

Question 23

make all the value stream visible, reduce or eliminate non-value added portion of the process, result: large time savings

Answer 23

Lean Focus of Lean Approach

Question 24

Time savings has direct impact on

Answer 24

cost, schedule, resources, capacity, flexibility, etc

Question 25

like a meandering stream with many stagnant pools, waterfalls, and eddies

Answer 25

Batch Production

Question 26

Doubling the production rate means doubling resources

Answer 26

Traditional thinking on Continuous flow

Question 27

Doubling production rates means halving the time waiting

Answer 27

continuous flow thinking on continuous flow

Question 28

was an even more valuable innovation of henry ford's than his better known 'mass' production model

Answer 28

"flow" production

Question 29

How does lean solve problems?

Answer 29

-Focuses on what is of VALUE to the customer -Eliminate activities that do not move the product close to its final form -Creates Continuous flow

Question 30

statistical phrase that denotes near or almost perfection

Answer 30

Six sigma

Question 31

anything outside specification limits represent quality losses

Answer 31

Traditional "Goalpost" Philosophy

Question 32

Any deviation from the target causes losses to society

Answer 32

Taguchi Philosophy

Question 33

How does six sigma solve problems?

Answer 33

-practical problem (Define/Measure) -statistical problem (Analyze) -Statistical solution (Improve) -Practical Solution (Control)

Question 34

Pass rates are declining

Answer 34

Practical Problem

Question 35

Y=f(x) Y= scores x= diff factors

Answer 35

Statistical problem

Question 36

3 sections of the exams are the highest trouble spots

Answer 36

Statistical Solution

Question 37

Focus training on 3 areas for inexperienced technicians

Answer 37

Practical Solutions

Question 38

six sigma aims to have ____% of values are within specifications

Answer 38

99.99966%

Question 39

reducing defects/ wastes

Answer 39

Lean Manufacturing

Question 40

reducing variation among processes

Answer 40

Six Sigma

Question 41

separate the value added from non value added activities

Answer 41

True

Question 42

8 types of wastes

Answer 42

Defects Overproduction Waiting Non-Utilized Talents Transportation Inventory Motion Extra Processing

Question 43

it has a direct impact to the work in process

Answer 43

batch flow

Question 44

requires more manual intervention, as the equipment needs to be set up and adjusted for each production run

Answer 44

Batch or Queue Processing

Question 45

Highly automated, less time required to produce individual item but cannot assure quality

Answer 45

Continuous Processing

Question 46

waste from product failure to meet customer expectations

Answer 46

Defects

Question 47

making more products that customer demands

Answer 47

OverProduction

Question 48

Waste from time spent

Answer 48

Waiting

Question 49

HR usually does not recognize people's expertise

Answer 49

Non-Utilized Talents

Question 50

unnecessary movement of products and materials

Answer 50

Transportation

Question 51

Excess products that are not processed

Answer 51

Inventory

Question 52

Wasted time and effort related to people's movements

Answer 52

Motion

Question 53

more work or higher quality than required

Answer 53

Extraprocessing

Question 54

he said "We all tend to concentrate on taking corrective actions that we know how to take, not necessarily concentrating on the problems we should correct and the actions needed to correct (them).”

Answer 54

Eliyahu Goldratt

Question 55

Empower them to make process changes to:

Answer 55

- Eliminate non-value-added steps - Keep adding value continuously without interruptions

Question 56

How to ask the right questions on how to gets started?

Answer 56

- What can we do to save time? - Not: What can we do to save money?

Question 57

How to get to the root causes?

Answer 57

5-Whys, etc.