LEAN Flashcards
1
Q
What is DMAIC in Lean ?
A
Define Measure, Analyze, Improve Control
2
Q
Which tools are included in DEFINE ?
A
Problem definition Project charter SIPOC
3
Q
Tools for MEASURE
A
- Data collection 2. Spaghetti diagrams 3. Swimlane diagrams 4. Value stream mapping 5. Process flow mapping
4
Q
Tools for ANALYZE
A
- Root cause analysis 2. 5 WHY’s 3. Pareto analysis 4. Capacity and bottleneck identification
5
Q
Tools for IMPROVE stage in LEAN (7 in total)
A
- 5S 2. Layout 3. Standard work 4. Poka Yoke 5. TPM 6. Takt time & pull 7. Kaizen
6
Q
Tools for CONTROL stage in LEAN
A
- Visual control 2. Audit & control plan 3. ROI
7
Q
What are requirements for Lean Project Goals ?
A
It must be: S - specific M - measurable A - attainable R - relevant T - time bound
8
Q
SIPOC steps
A
9
Q
Hierarchy of Process Discovery
A
10
Q
What are the benefits of SIPOC ?
A
11
Q
What is Value added thing ?
A
Something, what is customer willing to pay for
12
Q
What ar three rules of waste ?
A
13
Q
What are 8 types of waste ?
A
D - defect (rework and errors (documents and tools) )
O- overproduction (doing unncessary work not requested)
W- waiting (waiting for the next process)
N - non engaging employee (under utilized employees)
T - transportation (transport of documents & equipment which is not necessary)
I - inventory (obsolete, excess inventory, shortage of parts)
M - motion (unnecessary movements
E - extra processing (unnecessary processing, process of getting approvals..)
14
Q
8 types of waste
A
15
Q
What are three additional types of waste (except main 8 ) ?
A
- Inappropriate systems
- Wasted material
- Wasted Utility Resources
16
Q
What is Lead Time ?
A
17
Q
How to measure Degree of Leanness ?
A
18
Q
What is three point estimate ?
A
19
Q
Typical lean improvements
A
20
Q
What should included in all Lean metrics ?
A
- Strategic company goal
- Project goal (waste minimization)
- Customer requirements
21
Q
Why to collect data for lean ?
A
22
Q
What is Spaghetti Diagram ?
A
Spaghetti Diagram is graphical tool, used to depict the physical flow of work or material in a process.
23
Q
What is th most common applicatio of Spaghetti Diagram ?
A
Make movement of people more efficient,
24
Q
What is Swimlane Diagram ?
A
Cross-function mapping tool that visualizes the process flow by responsibility
25
What is RACI charting ?
A systematic technique for clarifying roles and responsibilities in a work activity within the process.
R - responsible (do the job. execute)
A- accountable (make the decision.take ultimate ownership)
C - consult (communicate in advanc)
I - inform (need to know, but don't have an impact on decision)
26
What are the benefits of using RACI charts ?
27
What are roles of Swimlane diagrams and RACI ?
28
Process flow map faciliate a greater understanding of a process by identifying .....
1. Bottlenecks
2. Redundancies
3. Key inputs and outputs
4. Key decision points for criteria
5. Roles and responsibilities
29
Process flow map describe .....
1. Major activities/tasks
2. Process workflow
3. Value added and non-value added steps
4. Process boundaries
5. Input variables (X's)
6. Output variables (Y's)
7. Where data is (or should be) collected
30
What is relation between VSM and Swimlane Diagrams regarding to Process Flow Maps ?
31
In a summary, what Process Flow Maps do ?
32
Describe Schlumberger Investigation Process
33
What is SCAT ?
Schlumberger's Systematic Cause Analysis Technique
Lack of Control \> Root Cause \> Immediate Cause \> Incident \> Loss
34
Describe 5 Whys process
35
There are two main types of action items: short term and long term. What are the main characteristics of action items ?
36
What is the criteria to find out, if action item resolves root cause ?
37
What is Fishbone diagram ?
Cause and Effect Diagram
38
What are main parts of Fishbone diagram ?
39
What is Pareto Principle ?
40
Describe Pareto Analysis
Pareto analysis may use both:
* Frequncy of occurence
* Total cost
Most frequently ocurring may not be the most costly one
Focus first on low project costs wth high impact
41
What is capacity ?
42
How to Improve System Capacity ?
1. Identify th system constraint
2. Develop a plan to mitigae the system constraint
3. Align every part of the system to support the constraints even if this reduces the efficiency of non-constrained resources
4. Elevate the system constraints. If output is still inadequate, acquire more of this resource
5. If the constraint has been broken go back to number 1
43
What is Nominal time ?
Nominal time = Total time - Planned downtime (lunch, break to refuel, etc..)
44
What is effective time ?
Effective time = Total Time - total downtime (planned, unplanned)
45
What is bottleneck ?
46
What 5S stands for ?
Sort
Set in order
Shin
Standardize
Sustain
47
What are requirements for Base Lean Layout ?
1. Single direction flow of truck traffic to avoid congestion and increase safey
2. Single direction flow on the shop floor from receiving to shipping
3. Equipment should maintain one orientation throughout all movements on the shop floor
4. Using tool carts reduces demand and lost time waiting for cranes or forklift
5. Wet and dry areas should be separated to minimize overspray, humidity, and contamination
48
What factors drive the effectiveness of the workplace ?
49
Critical design guidelines for layout (1 to 5)
1. Single flow of truck traffic
2. Single direction flow for equipment processing
3. Maintain one orientation (tools)
4. Motorized tool carts (reduce wait time for cranes, forklifts)
5. Separate wet and dry areas (humidity)
6. Third party inspection not to interrupt the process
50
What are critical design guidelines for layout (6 to 10)
* Third party inspection not to interrupt the process
* Schedule work based on "pull" system
* Work area of the next process should be adjacent to the previous process
* Mechanical workstation incorporates benches, shadow boards and carts that integrate with the bench
* Portable electrical benches
51
Describe 7 steps in layout design process
52
List advantages of Lean Layout in a summary
53
What is takt time ?
54
What is Volume Leveling in Tak Time ?
It is to reduce the variation in demand on any process
55
What is Mix Leveling in Takt Time ?
To reduce the variation in the mix of activities to be performed by establishing a set schedule
56
What choices exist for Volume Leveling Choices ?
1. Level volume by buffering (kanban)
2. Pull additional resources when required
3. Reduce the root cause for variation
57
What are Standardized Work Implementatin Process ?
1. Determine product/service family groupings and takt time
2. Observe and map the process
3. Identify Standard Work Process
4. Develop Stanard Work Package
5. Implement Standard Work Practices
6. Monitor Work Performance KPI
58
What is mistake proofing ?
Using process and/or design features to prevent errors or their negative impact. (Poka Yoke in Japanese)
59
What are benefits of Mistake Proofing ?
* Inexpensive
* Very effective
* Based on simplicity and ingenuity
* Ma
60
Describe Levels of Mistake Proofing
1. Level 1 : Defect / mistake cannot occur
2. Level 2: Defect can occur but will not be passed on
3. Level 3: Defect / Mistake is possible but there is a gauge (or device) to detect the problem and provide a reaction
61
What kind of errors/defects are addressed by Poka Yoke (Mistake Proofing) ?
Defects/errors caused by human mistakes
62
In summary, what is Push-Pull Kanban ?
* Push is traditional batch and queue
* Push maximizes individual process efficiencies
* Pull is consumption based processing
* Pull maximizes value stream effectiveness
* Flow where you can, pull where you must and never push
63
What Kanban means in Japanese ?
Signal
64
What are benefits of Visually Controlling activities with Kanban systems ?
* Allows the flow f work to be controlled
* Standardizes spare parts inventory (kanban)
* Extremely flexible when demand changes
* Highlights capacity and personnel requirements
* Reduces waste
65
What are rules of Kanban and Pull systems ?
1. Maintain equipment inventory to meet customer requirements (no extra)
2. Order spares only when the previous spare was taken and only as much as was taken
3. Maintain equipment to make sure you have equal or slightly greater than needed to meet customer requirements (no extra)
4. Use kanban as a fine-tuning device. Do not start too early or too late. Reduce the amount of kanbans over time
5. Stabilize and rationalize the process to fit with your ogranization's changing demand
66
What is Kanban in Lean ?
* It is a signal of process consumption
* It is a flexible, visual form of controlling work to be done or ready to support average operational needs
* Prevents overproduction
* Prioritizes the task
* Equipment control is easier
67
Describe process of taking decision to have Kaizen Event ?
68
Describe 4 phases of Kaizen Event
1. Planning and preparation
2. Implementation (the Event)
3. Presentation and Celebration
4. Follow-up and dissemination
69
What is Kaizen ?
Kai (to take apart) + Zen (to make good) = Kaizen (continuous improvement)
The kaizen concept focuses on each process or operation to add value and eliminate waste
70
What is most importan phase of Kaizen Event ?
4. Follow up and dissemination
71
What is Kaizen Event ?
A team activity that consist of the use of Lean methods to rapidly eliminate waste in a chosen area. Usually lasts 4-5 days.
Consist of 4 phases
72
What is Visual Management Improvement Cycle ?
73
What is the benefit of Effective Visual Controls ?
Anyone can walk into a workplace and visually understand the current situation
74
In summary, what Visual Controls provide ?
75
What are the benefits of having Audit and Control Plans in place ?
1. Control plans ensure that the process consistently meets customer requirements
2. They should provide predictive activities, so adjustments can be made before processes are out of control
3. They prevent the slippage of improvement progress
76
What is ROI ?
ROI (return on investmen) is a performance measure used to evaluate the efficiency of a single investment or compare the efficiency of a number of investments
77
What are benefits of LEAN ?
1. Reduced CAPEX
2. Increased efficiency
3. Lower costs and improve SQ
4. Improved Interfaces (between different departments)
78
What are two main types of projects in LEAN ?
1. With impact on customer service
2. With impact on reducing costs
79
What two main type of savings can be gained by LEAN projects ?
1. Hard savings - can be measured directly
2. Soft savings
80
What topics are covered in Lean Level 2 modules 1-5 ?
1. DMAIC & LEAN
2. Problem definition/Project Scope
3. SIPOC
4. Value & Waste
5. Lean Metrics
81
What topics are covered in Lean Level 2 modules 6-10 ?
6. Data Collection
7. Spaghetti Diagram
8. Swimlane / RACI
9. VSM map
10. Process Flow Maps
82
What topics are covered in Lean Level 2 modules 11-15 ?
11. Root Cause Analysis
12. Cause and Effect Diagram
13. Pareto Diagram
14. Capacity and bottleneck
15. 5S
83
What topics are covered in Lean Level 2 modules 16-20 ?
16. Lean Layout
17. Takt Time
18. Standardized Work
19. Mistake Proofing
20. Pull and Kanban
84
What topics are covered in Lean Level 2 modules 21-24 ?
21. Kaizen
22. Visual Control and Management
23. Audit and Control Plan
24. Benefits Capture and Project Value
85
## Footnote
What are characteristics of value added process ?
## Footnote
1. It is what customer is willing to pay for 2. Something is changed during the process 3. Done right first time
86
## Footnote
How to develop a good problem stating?
## Footnote
Problem stating (PS) : describe current situation. Use metrics to define impact. Be specific without including causes or solutions. Answer below open questions: 1. What is the problem? 2. Why is the problem? 3. Where is the problem? 4. How is and/or big the problem? 5. When is it the problem? 6. Who is it problem for?
