8 Wastes of Lean & Lean Six Sigma Principles

8 Wastes of Lean

• Administering incorrect doses to patients is classified as Defects.
• Moving patients from one hospital department to another is Transportation.
• Waiting for responses represents Waiting.
• People searching for materials, tools, or equipment is classified as Motion.
• When meals are created but not eaten or only partially eaten, this is overproduction.
• Entering the same piece of data in more than one place on a form or in software is extra processing.
• Inventory is cabinets that are full of office supplies.
• Assigning routine work to people with advanced skills defines Non-utilized talent.
• Patients in waiting rooms indicates Waiting.
• Creating extra report information classifies as Extra Processing.

Quiz

• Lean Six Sigma is not only applicable to quality related initiatives; the statement is False.
• DMAIC is an appropriate Lean Six Sigma approach to improving an existing assembly process.
• Lean originated in the 1940s from Toyota.
• Six Sigma originated in the 1980s from Motorola.
• Quality is defined by Customers.
• Lean Six Sigma is best described as All of the above.
• A waste triggered by non-conformity to requirements can be classified as a Defect.
• Steps or elements which should be eliminated from the process are classified as non-value adding activities so that organizations are more efficient and effective.
• Lean targets waste elimination while Six Sigma targets Reducing Variation.
• DMADV stands for Define – measure -analyze – design – verify .
• Yellow belt individuals have LSS belt levels and are tool experts that help GB project leaders in doing data analysis and initiative quick wins.

Define Phase

• Business Case explains the importance of doing a project.
• There are benefits that are associated with the goals of closing a GAP and is TRUE .
• SIPOC DIAGRAM is used to determine the boundaries of a process at its start.
• Problem Solving activity occurs to close the gap between the current state and the target state.
• An Improvement activity establishes a new baseline or target.
• Problems that recur but the solutions are not known are Significant.
• It is recommended to have between 5-7 process steps when creating a SIPOC Diagram.
• False denotes the problem statement "'Increasing rejection rate with an average of 5% vs target of 2% since WW20 to WW32 which is a gap of 3% due to Process X operators" is a correct problem statement."
• False is an Objective/Goal statement which must include the solution to the identified problem
• Consequential is the kind of metric which is said to be the risk assessment metric for a project.

Measure Phase

• The average fat is 16.46.
• There are 2 data points representing the mode in the % Fat dataset.
• The median % Fat is 16.40.
• The mode of the % Fat dataset is 16.3.
• The range of % Fat is 7.70.
• The average energy cost is 330.6.
• False denotes the statement "Median Energy Cost is greater than Mean Energy Cost".
• False denotes the statement that three data points represent the Mode Energy Cost.
• Standard deviation of Energy Cost is 154.2.
• Mode is not an applicable measure of central tendency in the Energy Cost dataset.
• An ellipse in a process map designates a Start and stop point.
• Measurement system analysis can be used to validate the reliability of the data source.
• A false statement about measurement is that data collection is only conducted in the Measure Phase of DMAIC.
• Operational Definition provides a common understanding of how a word/term is being used in the project's context.
• Height does not belong to the group.
• Interval is a measurement scale with ordered units having the same difference, but no absolute zero.
• Continuous measurements come from a continuum scale.
• Body temperature does not belong to the provided group.
• Accuracy is to central tendency while precision is to Dispersion.
• Median is a measure of central tendency that is preferred when there is an outlier or unusual observation.

Analyze Phase

• The median pulse rate for females is 80, while for males it is 76.
• Moderate Activity is the most significant contributor to pulse rate.
• The IQR of pulse based on Ran (Yes or No) is 30 & 13.5.
• There is no significant difference between the distribution of pulse based on whether the person is smoking or not smoking.
• There is a Possible Negative Correlation between Pulse and Height.
• There is a Possible Negative Correlation between Pulse and Weight.
• Moderate activity has an outlier pulse.
• 75% of male subjects in the study have a pulse rate that meets the standard of 70 to 100 BPM.
• 75 & 85 is the bin or interval with the highest number of frequencies for pulse.
• 2 is the bin or interval with the highest number of frequencies for pulse.
• Fishbone Diagram is used to discover potential things that could impact the output of the process being investigated.
• Box plot is a graphical tool used to compare distribution of data and the location of the central tendency in terms of the median.
• Pareto follows the 80-20 principle, stating that 80% of the effect is accounted for by 20% of the factors.
• Why-why analysis is not strict in asking a minimum of 5 whys and is False.
• Inter quartile range is a measure of the spread or data distribution in a box plot.
• Man is the last major cause that is explored in Root Cause Analysis.
• Of the provided options Time Series does not not belong to the group.
• Limits is not a pattern that can be highlighted by a time series chart.
• High lead time is affected by high preparation time, which can be explained by a Positive correlation.
• Skewed is a type of histogram caused by natural limits in the outcome of the process.

Improve Phase Quiz

• Cross Training can reduce bottlenecks due to human intervention.
• Visual management tools facilitate prevention or correction of errors in the process by making things obvious.
• The statement “5S can be done as stand alone improvement even outside Lean Six Sigma” is true.
• SMED Worksheet is not a variation of standard work.
• The arrangement that goes from good to best is Containment - Detection – Prevention.
• In a PICK Matrix, you KILL solutions with high effort but low impact.
• In a PICK Matrix, you PROCEED with solutions with low effort but high impact.
• IMPLEMENTATION PLAN is a guide on how to deploy the implementation of identified activities.
• EVALUATION TOOLS can aid in evaluating and displaying the results of the implemented solution and improvement.
• Box plots can be used to evaluate the effectiveness of implemented improvement actions.

Control Phase

• +/- 3sigma is the distance allowed for common causes of variation from the mean.
• True denotes that Special tests are used to examine trends, cycles, or shifts in data points to identify assignable causes.
• No is the best choice of control chart if there is a continuous data set and you have only been able to collect a group size of 15.
• Process Control Plan is a document you will return to if problems recur after project completion.
• True is the statement that control charts display variation in a process.
• Data should be randomly collected based on normal distribution.
• P chart should be used when an analyst counts the number of defective parts with varying sample sizes taken daily.
• Of the choices provided IX – MR does not belong in the group.
• A product that cannot perform its intended function is defective.

Review Quiz

• Lean Six Sigma is not only applicable to quality related initiatives; the statement is False.
• DMAC is an appropriate Lean Six Sigma approach to improving an existing assembly process.
• Lean originated in the 1940s from Toyota.
• Six Sigma originated in the 1980s from Motorola.
• Quality is defined by Customers.
• A waste triggered by non-conformity to requirements can be classified as a Defect.
• Lean targets waste elimination while Six Sigma targets Reducing variation
• Yellow Belt individuals have LSS belt levels and are tool experts that help GB project leaders in doing data analysis and initiative quick wins.
• Business Case explains the importance of doing a project.
• There are benefits that are associated with the goals of closing a GAP and is True.
• SIPOC DIAGRAM is used to determine the boundaries of a process at its start.
• It is recommended to have between 5-7 process steps when creating a SIPOC Diagram.
• False denotes the problem statement "'Increasing rejection rate with an average of 5% vs target of 2% since WW20 to WW32 which is a gap of 3% due to Process X operators" is correct."
• False is an Objective/Goal statement which must include the solution to the identified problem
• Consequential is the kind of metric which is said to be the risk assessment metric for a project.
• An ellipse in a process map designates a Start and stop point.
• Measurement System Analysis helps validate the reliability of the data source.
• A false statement about measurement is that data collection is only conducted in the Measure Phase of DMAIC.
• Fishbone Diagram is used to discover potential things that could impact the output of the process being investigated.
• Box plot is a graphical tool used to compare distribution of data and the location of the central tendency in terms of the median.
• Pareto chart follows the 80-20 principle, stating that 80% of the effect is accounted for by 20% of the factors.
• Cross Training can reduce bottlenecks due to human intervention.
• Mistake proofing tools facilitate prevention or correction of errors in the process.
• The statement “5S can be done as stand alone improvement even outside Lean Six Sigma” is true.
• +/- 3 sigma is the distance allowed for common causes of variation from the mean.
• True denotes that Special tests are used to examine trends, cycles, or shifts in data points to identify assignable causes.
• Yes is the best choice of control chart if there is a continuous data set and you have been able to collect a group size of 5
• Process Control Plan is a document you will return to if problems recur after project completion.
• P chart should be used when an analyst counts the number of defective parts with varying sample sizes taken daily.
• X Bar and R is the analyst can use a control chart to monitor the temperature in the facility
• A product that cannot perform its intended function is defective.