The Lean system that enables us to recognize the standard and any deviation from it, thus corrective actions can be taken immediately is called:
Hoshin Planning'
Kaikaku
Visual Management
TRIZ
Successful Control Plans utilize which of the following type action
Compensating
Reactive
Preventive
Select the proper sequence of the steps in the IMPROVE Phase
Pilot test, Select a solution, Implement full-scale, Generate creative solution idea
Implement full-scale, Pilot test, Generate creative solution idea, Select a solution
Generate creative solution ideas, Select a solution, Pilot test, Implement full-scale
Select a solution, Generate creative solution ideas, Implement full-scale, Pilot test
In the improved FMEA, select the factor that its rating can be changed only by the customer.
Failure
Severity
Occurence
Kanban is a Lean "Push" device that allows an efficient means to transfer parts from one department to another and automatically reorder products using minimum/maximum inventory levels.
Quality at the Source is an approach to quality that places the responsibility for preventing or detecting errors in the hands of suppliers.
Select the correct definition for External Elements of Machine Changeover.
Operations that must be performed while the machine/process is stopped.
Operations that can be performed while the machine/process is running.
The Single Minute Exchange of Die process focuses on converting INTERNAL to EXTERNAL activities and creating more machine run time.
The Lean term that refers to using ingenuity to create devices that allow us to do our job 100% error free 100% of the time is
Kanban
Mistake-Proofing (or Poka-Yoke)
Kaizen
Heijunka
Calculate the Overall Equipment Effectiveness Index of a machine which is available at 80% of the time, its performance efficiency is 90%, and produces at 100% First Pass Yield.
0.90
0.72
0.80
0.89
Select the proper term for Continuous Incremental improvement.
Muri
Poka-Yoke
Changeover time is the time elapsed between when the first good piece of product A comes off and the first good piece of product B starts.
In a value stream that includes a Push system, resources are provided to the consumer based on
Forecasts or schedules
Controlling the flow of resources by replacing only what has been consumed
Customer orders
In Hoshin Planning, the term "Catchball" means communication and socializing ideas.
In a value stream that includes a Pull system, resources are provided to the Customer based on
We can decide what type of control chart to use based on: 1) The types of data we have 2) What is counted (Defects, Defectives, Individuals, Rational Subgroups).
We have Variable Data and we count Individuals, what control chart can we use
X-bar & R chart
Individuals and Moving Range chart
X-bar and S chart
If we have Attribute Data and we count Defects, what two potential control charts can we use
c chart or u chart
u chart or p chart
u chart or np chart
c chart or np chart
c chart or p chart
In an FMEA analysis, the severity rating is 9, the occurrence rating is 3, and the detection rating is 3.
Calculate the Risk Priority Number (RPN).
15
81
3
9
5
27
The 5 Whys is a question-asking technique used to explore the root cause of a defect or problem.
At what single point in our Value Stream will we schedule production
The Pacemaker
At the End (as near as close to the Customer)
At the Beginning (as near as close to the Supplier)
The place to start introducing Continuous (or SINGLE-PIECE) Flow is usually at the beginning of the "pacemaker" Process in final assembly, from which the product can flow straight through to shipping.
When we analyze the Value Stream for improvement opportunities, one typical question is whether we will be producing directly to Shipping, or we will be producing to a finished goods Supermarket.
In order to build directly to Supermarket, select the one factor that is NOT part of the considerations.
The product is of very high value
Customer demand varies widely
The product is small enough and cheap enough to store cost effectively
The range of finished part numbers requiring changeovers in the Product Family is small
In order to build directly to Shipping, select the one factor that is NOT part of the considerations.
The product has many custom features
The product is very bulky, or is subject to spoiling
Hoshin Planning translates the strategic vision into tangible and measurable objectives for achieving the breakthrough.
In order to improve the capability of a process, the FIRST action we must take is:
Start adjusting the process around
Put the process On Target (Center it around the Mean)
Reduce the Variation
Cause and Effects (C&E) Matrix is a tool used to emphasize importance of Customer Requirements.
Relations Diagram, Cause & Effect Diagram, Cause and Effects (C&E) Matrix are generally used in Process Mapping.
Statistically, we can do many more potentially useful forms of analysis with continuous data versus discrete.
Most processes in the world result in a "Normal" Distribution
In a Normal Distribution, roughly 95% of the data are within a distance of HOW MANY standard deviations on either side of the mean.
1
2
6
Actual Process Variation is made up of the Observed Process Variation and the Measurement Variation.
To address actual process variability, the variation due to the measurement system must first be identified and separated from that of the process.
Cost of Poor Quality (COPQ) is a major measurement of the hidden factory.
Hidden Factory losses could contribute to what additional percentage of COPQ?
15-20%
1-5%
5-10%
10-15%
Process Mapping is a graphical illustration of the steps of the actual transactional or manufacturing process.
A Rectangle is used to show which of the following on a Process Map?
Decision Point
Start Point
Connector
Activity
A Rhombus is used to show which of the following on a Process Map
End Point
Waste is "anything other than the minimum amount of equipment, materials, parts, space, and worker's time which are absolutely essential to add value to the product [or service]."
Select the statement that best describes the MOTION type of waste.
Making more or faster than is needed
Extraneous, unnecessary actions or having to make repetitive, unnecessary movements
Redoing, Reworking, Repairing, or Scrapping the product or service just provided
Excessive movement and handling
People, material, and machines waiting for one another
Workplace Organization or 5S's is:
Spring Cleaning
Only to be done in manufacturing
A safe, clean, neat, arrangement of the workplace which provides a specific location for everything, and eliminates anything not required
Cleaning the facility every time a customer comes
Taking key items away from people which are used frequently
The phase of 5S (Workplace Organization) when "There should be a place for everything and everything should be in its place" is
Set in order
Sustain
Shine
Standardize
Sort
Physical Flow is used to give a quick visual representation for the movement of a part or associate (operator).
It is also referred to as a Spaghetti Diagram.
The phase of 5S (Workplace Organization) when "We Make it the Culture" is
In Eliyahu M. Goldratt's Theory of Constraint concept, a process is faster than its smallest bottleneck.
According to The SIX SIGMA WAY, one of the critical elements to the closed-loop business (Six Sigma) system is finding out which X variables have the most influence on the Y variables.
The Problem/Opportunity Definition must include a COMPLETE and DETAILED description of the problem that needs to be solved or a potential opportunity that needs to be exploited, and SHOULD also contain causes or solutions.
Having well defined Project Boundaries (BEGIN & END points) is not an important aspect of any Lean Six Sigma project.
There are three sequential steps in a process. The first pass yield at each step is as follows:
Step 1: 90%
Step 2: 80%
Step 3: 100%
The Rolled Throughput Yield (RTY) for this process is:
270%
90%
72%
100%
80%
A Value Stream Map is based on engineering standards or old information.
Which of the following is NOT an objective of Values Stream Mapping?
To see across the functional boundaries over which a product's value stream flows
To understand the linkage between the information flow and material flow
It ties together LEAN concepts and techniques
Improves customer response times and customer satisfaction
Promotes "cherry picking" and gut feel improvement initiatives
The Check (Tally) Sheet tool is used to
Monitor a process against its historical performance
Display variable data so that the pattern of variation can be identified
Identify relationships between two process variables
Provide an easy way to keep track of the frequency of occurrences
The Histogram tool is used to
Provide and easy way to keep track of the frequency of occurrences
The Scatter Diagram tool is used to
The Control Chart tool is used to
A bi-modal or multi-modal distribution is almost always a sign of a special cause of variation in the process or in the data collection technique.
Identify which of these flows is NOT part of a Value Stream
The FLOWCHART
The INFORMATION flow
The MATERIAL flow
The PRODUCTION (TRANSFORMATION) flow
For a specific Value Stream, the available time per day is 800 minutes and the Customer Demand is 200 units.
Then, the Takt Time at the Pacemaker step is:
1000
4
0.25
160,000
600
The Project Charter should be created as part of the DEFINE phase and remain unchanged for the life of the project.
Realistic goals must be SMART.
Select the word which is NOT part of what "SMART" stands for.
Aggressive
Specific
Timely
Relevant
Attainable
Measurable
Brainstorming is a way of generating radical ideas.
A Pareto Chart proves 80% of the problems cause 20% of the impact.
The Control Plan describes the actions required at each step in the process to assure that all process outputs will be in state of control.
Visual Management and Workplace Organization (5S) go hand-in-hand.
Force Field Analysis specifically can help us determine if a proposed change can get needed support.
The correct sequence of the steps in the Dr. Deming's Cycle is
Plan, Do, Check/Study, Act
Do, Plan, Act, Check/Study
Do, Plan, Check/Study, Act
Act, Plan, Check/Study, Do
Which company has had the fastest implementation of Six Sigma
Raytheon
Honeywell
Motorola
General Electric
Toyota
Six Sigma focuses on both the External and Internal Customers
The Six Sigma Improvement Methodology helps us identify and reduce/eliminate sources of variation.
Which one of James Womack's of LEAN Principles are we required to conduct FIRST?
Continuously improve in pursuit of perfection
Identify value stream and eliminate waste
Make value flow
Specify value in the eyes of the customer
Allow the customer to pull
LEAN is an umbrella program to create value to the customer by eliminating waste.
Variation characterized as normal "bouncing around" of any process is due to which cause?
Special or Assignable
Common or Controlled
None
In the concept of LEAN, SYNCHRONIZATION means
Ready capability to adapt to new, different or changing requirements in time and rate
The measure or beat of movement
A smooth uninterrupted movement
Arrange so that one set of elements exactly equals another
To cause to operate with exact coincidence
In the "4P" Model of the Toyota Production System, which statement best describes the PHILOSOPHY of the system?
The Heart and Soul of the Toyota Way
Add Value to Customers and Society
The Dynamic of the Toyota Way
Eliminate Waste through Flow and Standardization
In the "4P" Model of the Toyota Production System, which statement best describes the PROCESS of the system?
In the "4P" Model of the Toyota Production System, which statement best describes the PEOPLE and PARTNERS of the system?
In the "4P" Model of the Toyota Production System, which statement best describes the PROBLEM SOLVING of the system?
In the Concept of LEAN, FLEXIBILITY means
The focus of Six Sigma is on improving the MEAN of the process under study
There is a significant increase in defects when the Sigma number increases
Identify the one criterion that is NOT part of the criteria for Project Selection outlined in The SIX SIGMA WAY.
Results or Business
Certification
Organizational Impact
Feasibility
Who is considered the "Father of Six Sigma"
Bill Smith
Mikel Harry
Dr. Edward Deming
Jack Welch
Who is considered the Creator of the DMAIC Process and Deployment tactics ("Belts")
From the list below, identify the one case when an Affinity Diagram is NOT essential.
Facts or thoughts are certain
Facts or thought need to be organized
Unity within a team needs to be created
Ideas need to be clarified
