LEAN SIX SIGMA Methodology

Question 1

1. Focus on Customer Value, Waste Elimination, Speed, Flow and Resources
2. Focus on Customer value, Defect, Reduction, Reducing Variation, Repeatability and Consistency

Answer 1

1. Lean
2. Six Sigma

Question 2

• Seeks to improve the performance of a process by identifying and eliminating causes of defects and errors, resulting in eliminating variation in the process
• Seeks to identify, measure, and eliminate the large gaps of inefficiency in a process.

Answer 2

LEAN SIX SIGMA Methodology

Question 3

Model

1. Responsible for overall program management, aiding black belts.
2. Change agents, large project leaders, technical experts, key to the success of the overall programme.
3. Trained to understand of how to tackle variation. They are the engine of Lean Six Sigma and can tackle 80% of all Lean Six Sigma projects
4. Trained in overall methodology and basic problem solving concepts
5. Senior Leaders trained to recognise
   Project opportunities and Sponsor/Support Projects.

Answer 3

1. Master black belt
2. Black belts
3. green belts
4. Yellow belts
5. Senior leader

Question 4

Sigma scale

Answer 4

(%TEa-%Bias)/%CV

Question 5

In the highest level of westgard sigma control, the only error that can be committed is

Answer 5

random error

Question 6

GENERAL STEPS WITHIN EACH PHASE OF PROCESS IMPROVEMENT

Answer 6

Define
Measure
Analyze
Improve
Control

Question 7

DEFINE MEASURE ANALYZE IMPROVE CONTROL

(DMAIC)

1. Create charter
   ○ Purpose/goal
   ○ Specific outcomes
   ○ Activities
   ○ Project Scope
   ○ Team selection
2. Create SIPOC-hi level map
   ○ Supply - Input - Process - Output - Customer
3. Create VOC
   ○ Voice of Customer
   ○ Surveys
4. Use VOC present in CTQ tree
   ○ Critical to Quality – basically only take note of
   customer feedback that is critical to the quality
   and/or improvement of your project
5. Plan project including communication Plan

Answer 7

Define

Question 8

DEFINE MEASURE ANALYZE IMPROVE CONTROL

1. Map and analyze current process
2. Develop data collection plan
3. Collect baseline data
4. Calculate process sigma
5. Focus on charter and problem statement

Answer 8

MEASURE

Question 9

DEFINE MEASURE ANALYZE IMPROVE CONTROL

1. Brainstorm potential root causes
2. Select potential root causes
3. Cause and effect data
4. Verify Root Causes
   ○ Pareto Analysis
   ○ Histogram (Quantitative)
   ○ Box Plot
   ○ Scatter Plot
   ○ Ishikawa / Fishbone Diagram
   ○ Process Map Analysis

Answer 9

ANALYZE

Question 10

DEFINE MEASURE ANALYZE IMPROVE CONTROL

1. Develop potential solutions
2. Prioritize select solutions
3. Develop plans and pilot
4. Implement pilots
5. Develop full-scale implementation plans
6. Evaluate results

Answer 10

IMPROVE

Question 11

DEFINE MEASURE ANALYZE IMPROVE CONTROL

1. Document process changes
2. Develop SOPs, training (Standard Operating Procedure)
3. Implement solutions and ongoing process measurements
4. Initiate dashboard
5. Summarize lessons learned
6. Transition to process owner
   ● Goal of control is sustainability

Answer 11

CONTROL