lean six sigma amelia slater

RPM

Risk Priority Number is the product of indices from the previous three columns. RPM=P*S*D

DMADV

Define, measure, analyze, design, verify

Define

the project goals and customer deliverables

Measure

and determine customer needs and specifications

Analyze

the process options to meet the customer’s needs

Design

the process details to meet the customer’s needs

Verify

the design performance and ability to meet the customer’s needs

TOC

Theory of constraints. Effect cause effect, evaporating clouds, prerequisite trees

Seven Muda

Transportation, Inventory, Motion, waiting, overproduction, overprocessing, defects

Throughput

the rate at which the system generates money through sales

Inventory

all the money the system has invested in purchasing things it intends to sell

Womack

introduced the term lean production in book the machine that changed the world

value

must be defined by the customer

lean

target cost is the manufacturing cost if muda were eliminated

Target cost method (lean)

target selling price=target cost + selling expenses + profit

lean requires

conversion from batch process to continuous flow process or a one piece flow

Continuous flow

reduces cycle time, inventory, transportation

perceptual maps

appropriate questions to help quantify and prioritize the needs of the customer

Hauser

house of quality

cause and effect matrix

can help prioritize the importance of key process input variables

Juran

stated needs, real needs, perceived needs, cultural needs, unintended needs

QFD

Quality function deployment, the voice of the customer

Surveys should have

25-30 questions

Customer expectations

basic, expected, desired, unanticipated

Consumer v Business markets

Consumer-large number, small purchases, simple transaction, consumer not knowledgeable, supplier doesn’t share proprietary info. Business-small number, large transaction, customer may know more about requirements than producer, supplier may allow access to info

Customer retention

acquisition, retention, attrition, defection, reacquisition

Reacquisition

Highest cost

Business level

shareholders, top management, employees

Operations level

external customers who purchase the product, internal customers who manage production operations

Process level

primarily internal, frequent data collection

Team size

15-20 lose participation, 4 or less not enough ideas

Storming

consists of conflict and resistance to the groups task and structure. Conflict occurs

Norming

a sense of group cohesion develops

Six sigma teams

works on specific process or customer based projects of importance. Disbands upon project completion

DMAIC

Define, measure, analyze, improve, control

Measure

collect data to measure response variables

Analyze

identify root causes of defects

Improve

reduce variability or eliminate the cause

Control

monitor process to sustain improvements

heads 3/5 times

31%

10 units, 15%

complement of P(A)=0.2

0.8

0.51 defects