Six Sigma and Lean Methodologies

A comprehensive set of flashcards covering important vocabulary and concepts from Six Sigma and Lean methodologies.

Six Sigma

A methodology focused on reducing variation and defects in a process.

Lean

A methodology aimed at eliminating waste and improving flow.

DMAIC

An acronym for Define, Measure, Analyze, Improve, Control phases of Six Sigma.

TPS

Abbreviation for Toyota Production System.

Lean Six Sigma

A combined methodology that incorporates both Lean and Six Sigma principles.

Six Sigma belt levels

Hierarchy of training and certification in Six Sigma: White, Yellow, Green, Black, Master Black Belt.

Project Sponsor

An individual who supports and champions a project.

Project Manager

The person responsible for planning and executing a project.

Team Development Stages

The five stages teams typically go through: Forming, Storming, Norming, Performing, Transforming.

1.5 sigma shift

A correction applied to account for long-term process drift.

6σ

A measure indicating 3.4 defects per million opportunities (DPMO).

Sigma Level

A metric used to evaluate process capability.

Brainstorming

A technique for generating a large number of ideas without judgment.

NGT

Nominal Group Technique, a structured method for prioritizing ideas.

Multivoting

A method to narrow down a long list of ideas.

Fundamentals of Quality

Core principles: Customer focus, prevention, continuous improvement, employee involvement, fact-based decisions.

Quality

Consistently meeting customer requirements.

Cost of Quality categories

Four categories: Prevention, Appraisal, Internal Failure, External Failure.

Check Sheet

A structured data-collection tool.

Histogram

A graphical representation of data distribution.

Pareto Chart

A tool used to identify the most significant causes (80/20 rule).

Fishbone Diagram

A tool for root-cause identification.

Scatter Plot

A graph that shows the relationship between two variables.

Run Chart

A chart displaying performance trends over time.

Control Chart

A tool that detects process stability and variation.

Problem Statement

Needs to answer the questions: What, Where, When, Impact.

VOC

Stands for Voice of the Customer.

CTQ

Critical to Quality, a measurable requirement.

Stakeholder Analysis

A process used to identify and manage affected parties.

Stakeholder Ranking Criteria

Criteria based on Power and Interest.

SIPOC

A tool that outlines Suppliers, Inputs, Process, Outputs, and Customers.

Project Charter

A document that defines the scope, goals, roles, and alignment of a project.

RACI Chart

A tool to clarify roles and responsibilities.

Responsible

The person who does the work in a project.

Accountable

The person who owns the outcome and results.

Consulted

Those who give input into the project.

Informed

Those who need to be kept updated on project progress.

Affinity Diagram

A tool for grouping similar ideas or themes.

Critical Path

The longest sequence of dependent tasks in a project.

Measures of Central Tendency

Three statistical terms: Mean, Median, Mode.

Measures of Spread

Three metrics: Range, Variance, Standard Deviation.

FMEA

Failure Modes and Effects Analysis; identifies potential failures and prioritizes them with RPN.

RCA

Root Cause Analysis; a method for identifying the root causes of problems.

5 Whys

A technique for digging down to the root cause of a problem, created by Taiichi Ohno.

Type I Error

Also known as a false positive.

Type II Error

Also known as a false negative.

Significance Level

A typical threshold used in hypothesis testing, commonly set at 0.05.

Improve Phase Goal

To implement solutions that address validated root causes.

PICK Chart

A tool for ranking solutions based on effort and impact.

Pilot Test

A small-scale trial run of a proposed solution.

Future-State Map

A process map illustrating planned improvements.

Update FMEA in Improve Phase

To evaluate risks associated with new process implementations.

Control Phase Goal

To sustain improvements and prevent regression.

Control Plan

A document that specifies how a process is monitored.

Update SOPs

To institutionalize the improved process.

Control Charts

Used to monitor the stability of improved processes over time.