SCM Ch. 10 Flashcards

What is Lean?

A management approach focused on creating customer value through efficient use of resources.

What is Six Sigma?

A quality management method that uses data and statistical analysis to reduce defects and variation.

What is Lean Six Sigma?

A combined approach that integrates Lean efficiency with Six Sigma quality improvement.

What are the six tenets of Lean philosophy?

Elimination of waste; broad view; simplicity; continuous improvement; visibility; flexibility.

What does elimination of waste mean in Lean philosophy?

Removing all activities that do not add value to the customer.

What does a broad view mean in Lean philosophy?

Aligning all tasks with overall organizational goals.

What does simplicity mean in Lean philosophy?

Using the simplest possible solutions.

What does continuous improvement mean in Lean philosophy?

Constantly improving processes over time.

What does visibility mean in Lean philosophy?

Making problems visible so they can be identified and solved.

What does flexibility mean in Lean philosophy?

Ability to quickly adapt to changes in customer demand.

What are the main elements of Lean?

Lean production; Total Quality Management (TQM); respect for people.

What is Lean production?

A system focused on efficient operations and minimal inventory

What is Total Quality Management (TQM)?

An organization-wide effort to improve quality and eliminate defects.

What does respect for people mean in Lean?

Recognizing employees as critical resources and involving them in improvement processes.

What are the main components of Lean production?

Pull system; visual signals; small lot production; uniform plant loading.

What is a pull system in Lean production?

A system where production is based on actual demand rather than forecasts.

What is a push system?

A system where goods are produced based on forecasts and stored for future demand.

What is a kanban?

A signaling system used to communicate demand between workstations in a pull system.

How do kanban systems work?

An empty container with a kanban is sent upstream to signal production of more items.

What is small lot production?

Producing small quantities at a time to increase flexibility and responsiveness.

Why does small lot production require reduced setup time?

Frequent production changes require quick transitions between tasks.

What is uniform plant loading?

A method of smoothing production schedules to avoid large fluctuations.

What is the role of workers in Lean systems?

Workers perform multiple tasks

What is jidoka?

The authority of workers to stop production to fix problems immediately.

What are quality circles?

Teams of workers that meet to solve quality problems.

What is the role of management in Lean?

Creating a supportive culture that encourages continuous improvement.

What is the role of suppliers in Lean?

Building long-term relationships and often using fewer

What is Total Quality Management (TQM)?

An integrated approach focused on improving quality at all organizational levels.

What is the voice of the customer (VOC)?

Defining quality based on meeting or exceeding customer expectations.

Who are the key quality gurus in TQM?

W. Edwards Deming; Philip Crosby; Joseph Juran.

What did W. Edwards Deming contribute to quality management?

Developed 14 points and emphasized management responsibility for quality.

What did Philip Crosby contribute to quality management?

Promoted zero defects and the idea that quality is free.

What did Joseph Juran contribute to quality management?

Defined quality as fitness for use and introduced cost of quality.

What are the four categories of quality costs?

Prevention; appraisal; internal failure; external failure.

What are prevention costs?

Costs incurred to prevent defects.

What are appraisal costs?

Costs of inspecting and testing products for defects.

What are internal failure costs?

Costs of defects found before reaching the customer.

What are external failure costs?

Costs of defects found after reaching the customer.

What are the main quality tools used in TQM?

Cause-and-effect diagrams; flowcharts; checklists; control charts; scatter diagrams; Pareto analysis; histograms.

What is a cause-and-effect diagram?

A tool used to identify root causes of quality problems.

What is a flowchart?

A diagram showing steps in a process.

What is a checklist in quality control?

A list used to track defects and their frequency.

What is a control chart?

A chart used to monitor whether a process is within normal variation.

What is a scatter diagram?

A graph showing the relationship between two variables.

What is Pareto analysis?

A method to identify the most important causes of problems.

What is a histogram?

A chart showing the frequency distribution of data.

What is ISO 9000?

A set of international standards for quality management systems.

What are the benefits of ISO 9000?

Reduced waste; improved efficiency; better customer satisfaction; stronger reputation.

What is statistical quality control (SQC)?

The use of statistical methods to monitor and control quality.

What are the three categories of SQC?

Descriptive statistics; statistical process control (SPC); acceptance sampling.

What is statistical process control (SPC)?

Monitoring processes to ensure they operate within expected limits.

What is acceptance sampling?

Randomly inspecting a batch to decide whether to accept it.

What are the two types of process variation?

Assignable variation and common variation.

What is assignable variation?

Variation caused by identifiable and controllable factors.

What is common variation?

Natural variation inherent in a process.

What is process capability?

The ability of a process to meet product specifications.

What are product specifications?

Acceptable ranges of product quality characteristics.

What is Cp?

A measure of process capability comparing specification limits to process variation.

What is Cpk?

A measure of process capability that accounts for how centered the process is.

What is a control chart?

A graph used to monitor process performance over time.

What are control charts for variables?

Charts for measurable

What are control charts for attributes?

Charts for countable

What is a p-chart?

A control chart that tracks the proportion of defective items.

What is Six Sigma quality?

A method aiming for near-zero defects (3.4 defects per million).

What are the two aspects of Six Sigma methodology?

Technical tools and employee involvement.

What is DMAIC?

A structured problem-solving method: define

What does Define mean in DMAIC?

Identify the quality problem.

What does Measure mean in DMAIC?

Measure current process performance.

What does Analyze mean in DMAIC?

Identify root causes of problems.

What does Improve mean in DMAIC?

Implement solutions to eliminate causes.

What does Control mean in DMAIC?

Maintain improvements over time.

What is a Lean Six Sigma supply chain?

A system that integrates Lean and Six Sigma across all supply chain stages.

What are the steps to develop a Lean Six Sigma supply chain?

Define value; analyze capability; develop metrics; implement improvements.

How does Lean Six Sigma impact suppliers?

Improves responsiveness

How does Lean Six Sigma impact operations?

Improves efficiency and optimizes inventory usage.

How does Lean Six Sigma impact logistics?

Optimizes transportation