Lean Six Sigma Fundamentals and Methodology

Practice flashcards covering the fundamentals, principles, methodologies (DMAIC), tools, and roles of Lean Six Sigma based on the lecture transcript.

What are the primary differences in focus between Lean and Six Sigma?

Lean focuses on waste reduction and uses less-technical tools like kaizen, while Six Sigma emphasizes variation reduction through statistical data analysis and process control.

In the context of Implementing Six Sigma, what characterizes 'Option 2: Build a Six Sigma System'?

This method teaches a full process where employees called Black Belts are trained over several months while working on real company projects to pick the right tools for the right project.

What is the definition and formula for Takt Time?

Takt Time is the rate at which a finished product must be completed to meet customer demand. Formula: $\text{Net Available Time} \div \text{Customer Demand} = \text{Takt Time}$

How is 'Value' defined in Lean Six Sigma from the customer's perspective?

Value is specific product, service, or feature a customer is willing to pay for that fulfills their needs at the right time and price, maximizing utility while eliminating waste (muda).

What are the five principles of Lean as defined by Womack and Jones in 'The Machine That Changed the World'?

1) Defining value, 2) mapping the value stream, 3) creating flow, 4) using a pull system, and 5) pursuing perfection.

What are the two types of process variation identified in Six Sigma?

Special cause variation, which is caused by external factors, and Natural variation, which is random variation present in the process.

What is the objective of the 'Define' phase in the DMAIC methodology?

To lay the project's foundation by defining the problem, project goals, and customer requirements, and creating a project charter.

What does the acronym DOWNTIME stand for in Lean waste reduction?

Defects, Overproduction, Waiting, Non-utilized talent, Transportation, Inventory, Motion, and Extra-processing.

Who introduced the combined Lean Six Sigma strategy and in what year was their book published?

Michael George and Robert Lawrence Jr. introduced the strategy in their 2002 book 'Lean Six Sigma: Combining Six Sigma with Lean Speed'.

What is the difference between Cycle Time and Lead Time?

Cycle Time is the time required to complete an individual task, while Lead Time is the total elapsed time from when a customer places an order until they receive the goods or services.

What specific defect level does Six Sigma strive to achieve?

A level of just $3.4$ defects per million opportunities.

Name the components of a SIPOC diagram.

Suppliers, Inputs, Process, Outputs, and Customers.

What is a Pareto Chart and how are its bars arranged?

A Pareto Chart is a bar graph representing frequency or cost where the longest bars are arranged on the left and the shortest to the right.

What are the five steps of the 5S Movement?

1. Seiri / Sort, 2. Seiton / Straighten, 3. Seiso / Shine, 4. Seiketsu / Standardize, and 5. Shitsuke / Sustain.

Describe the role of a 'Green Belt' in the Six Sigma belt system.

Advanced practitioners who lead or support improvement projects with a comprehensive understanding of Lean Six Sigma tools and methodologies.

Define 'Process Capability' in Six Sigma.

The ability of a process to produce output within specification limits by understanding and quantifying variability.

What are common challenges mentioned for implementing Lean Six Sigma?

Resistance to change, lack of leadership support, inadequate training and resources, difficulty in data collection and analysis, and lack of a continuous improvement culture.

What is the purpose of a Fishbone Diagram (Ishikawa diagram)?

To identify many possible causes for an effect or problem and structure brainstorming sessions by sorting ideas into useful categories.

What is 'Mistake Proofing' or 'Poka-yoke'?

A tool used in the Control phase of DMAIC to make errors impossible or immediately detectable.

How do Lean and Six Sigma work together to reduce operational costs?

Lean makes processes faster and more efficient by eliminating waste, while Six Sigma makes them more effective and error-free by reducing variation.