32 Questions
What is the primary goal of the Lean Six Sigma approach?
To eliminate resource waste and defects
What is the first step in the Six Sigma approach?
Define the problem
What is the purpose of the 'Measure' step in Six Sigma?
To collect data on current performance and issues
What is one of the benefits of implementing a 5S system?
Reducing waste from unnecessary motion
What is the purpose of the 'Control' step in Six Sigma?
To refine the new process and continue monitoring
What is the main objective of waste minimization techniques in the engineering workplace?
To minimize waste and reduce environmental impact
What is the result of consistently maintaining equipment in a 5S system?
Reducing downtime and improving quality
What is the purpose of a workplace scan in the engineering workplace?
To make improvements to workplace organization
What is the main purpose of the 'Sort' step in a 5S system?
To remove unneeded clutter and eliminate distractions
What should be done with items that are 100% not needed in the workspace?
Discard, recycle, or donate them
What is the purpose of a 'red tag' holding area?
To organize items by review month
What is the benefit of creating a safer work environment through a 5S system?
Fewer accidents and injuries
What is the main goal of implementing a 5S system?
To engage operators by granting them more responsibility
What should be done with items that are used in another work area?
Deliver them to the team member responsible for that work area
What is the purpose of the 'Straighten' step in a 5S system?
To organize items in a specific order
What is one of the benefits of removing waste from the workspace?
Increased productivity
What is the primary focus of the Shine step in the 5S process?
Thoroughly cleaning and inspecting tools and equipment
What is the benefit of having a clean work environment according to the Shine step?
It makes it easier to spot emerging issues
What is the guiding principle of the Shine step?
Clean to understand
What is the primary goal of the Straighten step in the 5S process?
To reduce waste from excess motion
What is the benefit of placing frequently used items within easy reach?
It increases productivity by reducing motion
What is the purpose of inspecting each item after cleaning in the Shine step?
To determine if it needs updating, maintenance, or repair
What is an example of an activity that can be done in the Shine step?
Wipe down equipment
What is the purpose of grouping like items together during the Straighten step?
To brainstorm the best way to organize and store each category
What is the benefit of using visual designs, such as shadow boards, during the Straighten step?
It makes it easier to identify when an item is missing or misplaced
What is the purpose of the Standardize step in the 5S process?
To create a bridge between the first three 5S steps and the last step
Why is Standardize necessary in the 5S process?
It transforms 5S from a one-off project to a reproducible set of activities
What is the purpose of using containers during the Straighten step?
To organize items that are appropriate for containerization
What is the activity described in the Standardize step?
Document in pairs
Why is it important to plan a 5S team meeting with a focus on straightening at the one and two week points?
To brainstorm further improvements
What is the benefit of dedicating a surface or area entirely to shadow boxes and tool storage?
It makes it easier to find and access tools
What is the primary focus of the Straighten step in the 5S process?
Sorting and organizing items
Study Notes
Learning Outcomes
- Implement waste minimization techniques in the engineering workplace.
- Make improvements to workplace organization using a workplace scan.
- Employ methods of visual management in the engineering workplace.
Lean Six Sigma Approach
- A team-focused managerial approach that seeks to improve performance by eliminating resource waste and defects, as well as deviations from standards.
- 5 steps for Six Sigma:
- Define the problem: Craft a problem statement, goal statement, project charter, customer requirement, and process map.
- Measure the current process: Collect data on current performance and issues, verify data reliability, and update the project charter as needed.
- Analyze the cause of issues: Examine the process and data, display the data, investigate and confirm the issues, and continue updating the project charter as needed.
- Improve the process: Decide on solutions to fix issues, create process maps for new solutions, and implement the new fixes.
- Control: Refine the new process, continue monitoring, and use findings elsewhere in the business if possible.
5S Technique
- 5 benefits of a 5S system:
- Create space within the facility by removing unnecessary tools and equipment.
- Reduce downtime and improve quality by consistently maintaining equipment.
- Reduce waste from unnecessary motion by organizing the workspace.
- Engage operators by granting them more responsibility for their work environment.
- Create a safer work environment by ensuring it is clean and well-maintained.
5S Steps
SORT
- Separate items in the workspace that are needed from items that are not needed or may not be needed.
- Move unneeded items to a "red tag" holding area.
- Reasons to sort: remove unneeded clutter, eliminate distractions, and open up space for other uses.
- Items to sort:
- Items needed in this work area.
- Items needed in another work area.
- Items you may need (use the 5S "red tag" system).
- Items you do not need (discard, recycle, or donate).
STRAIGHTEN (Set to Order)
- Thoroughly organize the items that remain after sorting, making frequently used items easily accessible.
- Reasons to straighten: reduce waste from excess motion, provide easy access to frequently used items, and open up space.
- Straighten steps:
- Provide easy access to frequently used items.
- Group like items.
- Utilize visual designs.
- Use containers.
- Be agile.
SHINE
- Elevate the work area by ensuring thoroughly cleaned and inspected tools, equipment, and other items.
- Reasons to shine: engage and empower operators, give them more responsibility and agency over their work area, and identify problems before they interfere with production.
- Shine steps:
- Clean the work area.
- Find the source of problems (e.g., leaks, spills, unexpected wear).
- Inspect each item after cleaning.
STANDARDIZE
- Capture best practices for 5S as standardized work for the team.
- Reasons to standardize: make 5S repeatable, transform 5S from a one-off project to a reproducible set of activities.
- Standardize steps:
- Document in pairs.
- Establish procedures for 5S activities.
Learn about the Lean Six Sigma approach, a team-focused managerial method that aims to improve performance by eliminating waste and defects in the engineering workplace.
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