yellow belt review

Question 1

what is Heijunka?

Answer 1

process leveling in value stream

Question 2

what is Kaizen?

Answer 2

make better (cont improvement)

Question 3

IRS?

Answer 3

Increase efficiency, Reduce Cost, Save time

Question 4

what is jidoka?

Answer 4

stop the line, machines with human oversight

Question 5

what does JIT reveal?

Answer 5

exposes problems early

Question 6

what are the 3 components of the toyota house of quality foundation?

Answer 6

heijunka, SOP, kaizen

Question 7

toyota house of quality is the ______?

Answer 7

the WHAT

Question 8

the toyota way is the _____?

Answer 8

the HOW

Question 9

what is the toyota way?

Answer 9

(2nd house) continuous improvment and respect for people . the How

Question 10

starting a Lean project involves this very first action…

Answer 10

value stream mapping is the line of departure, it IDs the processes involves

Question 11

Taiichi Ohno highlights

Answer 11

post ww2 era, initiated the idea of lean ( he did not use the word lean however)
identified the 7 wastes (Muda)

Question 12

Bill Smith highlights

Answer 12

six sigma organizer (sigma is just math, he structured the process tools). Eng that applied stats to six sigma

Question 13

Jack Welch highlights

Answer 13

GE exec in mid 80s perfected six sigma and saved 11 billion over 10 years

Question 14

Vilfredo Pareto highlights

Answer 14

lean is influenced by him. observed that 80% of something is done by 20% of people etc

Question 15

Walter Shewart highlights

Answer 15

special cause— comman cause analysis. concentrate on the comman causes to reduce waste.
gave us the PDCA model for lean problem solving

Question 16

Henry Ford highlights

Answer 16

created with the assembly line

Question 17

Fredrick Taylor highlights

Answer 17

there is only one best way to do something. standardized processes.

Question 18

W. Edward Deming highlights

Answer 18

TQM pioneer to japan, US business did not want his interference. SOP, process controls etc. Japan post ww2 embraced him and exploded in quality and sales. 1973 us business started paying attention.

Question 19

Dr Kaoru Ishikawa highlight

Answer 19

founded the Fishbone assessment diagram

cause and effect

Question 20

Dr. Shigeo Shingo

Answer 20

Poke Yoke (mistake proofing idea) annual Lean award presented in his name

Question 21

define value added activity

Answer 21

something that changes the shape or form of a product into something a customer s willing to pay for.

Question 22

other benefits of Lean in addition to the IRS top 3.

Answer 22

lower cycle time, increased associate engagement, lower inventory levels,career pathing, remain comtetive in marketplace

Question 23

what is DMAIC

Answer 23

define; measure; analyze; improve; control

Question 24

what are some Improve outputs (from dmaic)

Answer 24

future state VSM, improved matrix, pilot studies

Question 25

what are some Analyze outputs (fm dmaic)

Answer 25

VA, NVA analysis, id of inputs, statistically test all inputs, validation of critical X's

Question 26

what are some Measure outputs (fm dmaic)

Answer 26

VSM, fish bone, dpmo, sigma value, histogram

Question 27

what are some Define outputs (fm dmaic)

Answer 27

projrct charter, stakeholder analysis, gantt-- project schedule, sipoc, voc matrix

Question 28

what defect percent is 6 sigma?

Answer 28

3.4 defects per million opportunities -- considered perfect

Question 29

the place where value is created....

Answer 29

The Gemba (go see, ask why, show respect)

Question 30

use of an A3....

Answer 30

strategy, problem solving, budgets, idp/pdp, procurement, etc meant to tell the story, all on one side of a page

Question 31

Y axis, X axis

Answer 31

value, time

Question 32

name the 4 basic problem solving approaches

Answer 32

kaizen (just do it action items), rapid improvement event, PDC/SA , DMAIC DMADV

Question 33

what is a "problem"?

Answer 33

it is an deviation from the standard, a gap between actual and desired/targetted conditions, an unfulfilled customer need.

Question 34

3 reason why problem solving is important

Answer 34

1. drives Continous improvement 2. engages people in the change process 3. provides better care and outcomes for our customers

Question 35

explain the 5 Whys.

Answer 35

in a fishbone diagram concept, asking Why at least 5 times of the current state tends to get to a root cause that can be addressed

Question 36

3 root cause tools

Answer 36

pareto chart, 5 Whys, Cause Effect diagram

Question 37

name the 3 rules of zero defects...

Answer 37

never accept a defect; never cause a defect; never pass a defect

Question 38

list benefits of kanban(6 of them)

Answer 38

its a simple work order of what to work on replacement info seen at a glance gives direction based on actual conditions in workspce prevents extra paperwork prevents over producing controls and reduces inventory costs

Question 39

kanban signals....

Answer 39

low levels of inventory

Question 40

standization benefits, list some (there are at least 8)

Answer 40

``` improves safety maintains quality reduces cost increases productivity stabilzes deliveries eliminates waste and simplfiies processes improves employee morale and engagement helps to reveal problems ```

Question 41

Mr Ohno said, " without standards there can be no...."

Answer 41

.... kaizen

Question 42

motion economy is ,......

Answer 42

seeks to combine, eliminate, reduce and smooth (CERS) motion. it considers the work place arrangements such as placement of tools, supplies, and equipment to reduce motion

Question 43

5 S include

Answer 43

sort, straighten, shine, standardize, sustain

Question 44

3 benefits of 5 S....

Answer 44

IRS increase efficiency, reduce waste and clutter, safety increased

Question 45

LSS definition!

Answer 45

LSS is a business strategy of creating and sustaining value for a customer by identifying value streams and eliminating waste.

Question 46

define Value stream...

Answer 46

for s good: from the time the customer places and order until the time the customer receives the product.

Question 47

3 levels of value streamss

Answer 47

process door to door enterprise

Question 48

Heijunka def...

Answer 48

leveling: creates static work loads to avoid dramatic shifts in swings in production

Question 49

give 3 types of heijunka...

Answer 49

one piece flow (vs batch and queue) (push vs) pull at the end of the value stream fifo