Defects and Metrics
What is a defect in Six Sigma?
A defect in Six Sigma is any instance where a process fails to meet customer specifications or expectations.
What is cycle time?
Cycle time is the total time required to complete one unit of a process, from start to finish.
What are the components of COPQ?
The components of COPQ include internal failure costs, external failure costs, appraisal costs, and prevention costs.
What are the different Six Sigma levels?
The Six Sigma levels are White Belt, Yellow Belt, Green Belt, Black Belt, and Master Black Belt.
What is yield in the context of Lean Six Sigma?
Yield in Lean Six Sigma refers to the percentage of defect-free units produced in a process.
What does DMAIC stand for?
DMAIC stands for Define, Measure, Analyze, Improve, and Control.
What factors can affect cycle time?
Factors affecting cycle time include process bottlenecks, resource availability, inefficiencies, rework, and variability in demand.
How does COPQ affect overall profitability?
COPQ reduces profitability by increasing rework, warranty claims, customer dissatisfaction, and inefficiencies.
What is a Green Belt?
A Green Belt is a Six Sigma practitioner who leads smaller projects and supports Black Belts in process improvement efforts.
How do you calculate yield?
Yield is calculated as (Total units produced - Defective units) / Total units produced × 100%.
What is the defect rate goal in Six Sigma?
The defect rate goal in Six Sigma is 3.4 defects per million opportunities (DPMO).
How can reducing cycle time impact efficiency?
Reducing cycle time increases efficiency, reduces waste, lowers costs, and improves customer satisfaction.
What is the difference between internal and external failure costs?
Internal failure costs occur before a product reaches the customer (e.g., scrap, rework), while external failure costs occur after delivery (e.g., warranty claims, reputation damage).
What is the role of a Black Belt in Six Sigma projects?
A Black Belt is responsible for leading Six Sigma projects, mentoring team members, and driving process improvements.
What is first-pass yield?
First-pass yield (FPY) is the percentage of products that meet quality standards without requiring rework.
How do you measure process performance?
Process performance is measured using metrics such as DPMO, yield, sigma level, cycle time, and control charts.
What is takt time?
Takt time is the rate at which a product must be completed to meet customer demand, calculated as available production time divided by customer demand.
How can reducing COPQ benefit an organization?
Reducing COPQ leads to lower costs, higher efficiency, better quality, and improved customer satisfaction.
What distinguishes a Master Black Belt?
A Master Black Belt is a highly experienced Six Sigma leader who trains Black Belts, oversees multiple projects, and provides strategic guidance.
What is the significance of overall yield?
Overall yield indicates process effectiveness and efficiency, showing how well a system produces defect-free products.
What is the purpose of a control chart?
The purpose of a control chart is to monitor process stability and detect variations over time to ensure consistent quality.
How do Lean and Six Sigma concepts relate to cycle time?
Lean focuses on eliminating waste to reduce cycle time, while Six Sigma reduces defects and variability, making processes more predictable and efficient.
Describe a strategy to minimize COPQ.
A strategy to minimize COPQ includes implementing proactive quality control measures, root cause analysis, and continuous improvement (DMAIC approach).
How do Six Sigma levels impact project success?
Six Sigma levels impact project success by defining clear roles and responsibilities, ensuring effective training, and fostering a culture of continuous improvement.
How can yield calculations inform process improvements?
Yield calculations help identify areas for improvement, reduce defects, and enhance process efficiency, leading to cost savings and higher quality.