PROBLEM SOLVING STRATEGIES
The 5 Problem Solving Steps that together can be used when applying Lean and Six Sigma methodologies
Define - Measure - Analyze - Improve - Control
Value is from the point of view of ________
The Customer
Name at least 4 of the 8 wastes (Muda)
TIMWOODS: Transportation, Inventory, Motion, Waiting, Overprocessing, Overproduction, Defects, Skills
_________ is a tool that defines the Customer and Suppliers of a process, and their respective requirements
A SIPOC
Name two tools that can be used to find root cause
Fishbone and 5 Why
____________ is a systematic methodology that uses data analysis to reduce process variability and to improve business performance
Six Sigma
The time it takes for one piece to move all the way through the process from start to finish (often referred to as "elapsed time")
Lead Time
What is a Gemba walk?
Going to where the work is being done and observing the process for waste
_____ is a tool that visually summarizes a problem and improvement plan. Elements can include a problem statement, background and current conditions, root cause analysis, expected benefits, deliverables, and performance metrics.
A3 Report
CTQ stands for _______
Critical to Quality
__________ a mindset/philosophy to increase customer value through the elimination of waste
Lean
There are 420 available minutes per day. Customer demand is 1000 units per day. What is the takt time?
0.42 minutes
Work that does not add value to the customer but is necessary is called what?
Incidental or Necessary Non-Value Added Activities
___________ is a visualization of distinct workflow steps such as tasks, decision points, process start and end points. It is used to describe sequential or related work activities
Process Mapping
__________ shows the detailed physical flow of the work and the material in a process, useful to improve the layout of a work area
A Spaghetti Diagram
In Problem Solving, 4W2H stands for __________
Who, What, Where, When, How much, How often
Normal distribution
Value add activities are defined as an activity that changes the ____, ____, or ____ of the product or service.
Form, fit, function
_______ is a high level visualization of an end to end process, depicting the main material and information flows. It can be used when developing strategic improvement plans.
Value Stream Mapping
When analyzing a measurement system, _______ refers to the average deviation from the known, true value.
Components of the Continuous Improvement (or "CI") Cycle
1) Standard Work
2) Visual Control
3) Problem Solving
4) Counter Measure
Six Sigma quality level is equivalent to a defect rate of _______ Parts Per Million (PPM)
3.4 Parts Per Million (PPM)
Name at least three practices or techniques that can be used to see/observe waste
Daily Management/Work Center Team Meetings, Genba Walks, Metrics, Customer Feedback, Visual Controls, Periodic Assessments (e.g. 5S), Safety Walks, Value Stream Mapping, Process Mapping, SIPOC, Standard Work, Spaghetti diagram
__________ is a visual display depicting the number of people and the cycle times at each step of a particular process
Operator Balance Chart
Name at least three practices or techniques that can be used to eliminate waste
Options include: 5S, Visual Management, Standard Work, Mistake Proofing, Workload Balancing, Kaizen Events