Six Sigma and Lean Process Management

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Questions and Answers

What is the primary focus of the course?

Service centric

Product centric

Customer centric

Process centric (correct)

What is the ultimate goal of 5S?

To generate value without wastage (correct)

To reduce waste

To increase productivity

To improve product quality

What is the correct sequence of the 5S methodology?

Standardize, Sustain, Shine, Set in order, Sort

Sort, Set in order, Shine, Standardize, Sustain (correct)

Shine, Set in order, Sort, Standardize, Sustain

Sustain, Shine, Set in order, Sort, Standardize

What is the main benefit of implementing 5S?

Generating value without wastage Signup and view all the answers

What phase of Six Sigma is most relevant to 5S?

Control Signup and view all the answers

What is the primary role of an individual in process performance improvement?

To improve processes through Lean and Six Sigma Signup and view all the answers

What is the purpose of the 5S methodology?

To create commitment and ownership Signup and view all the answers

What is the expected outcome of implementing the 5S methodology?

Higher productivity Signup and view all the answers

What is the primary focus of the 5S process?

To reduce wastage and improve quality and safety Signup and view all the answers

What is the significance of 5S in world-class manufacturing?

It is a core element of lean thinking and a fundamental platform Signup and view all the answers

What is the nature of the 5S process?

It is a continuous process Signup and view all the answers

What is the purpose of the regular team meeting led by the area manager?

To decide on the final location of all items in the area Signup and view all the answers

What is the importance of consistency in the 5S process?

It is crucial Signup and view all the answers

What is the relationship between the 5S process and the 7 types of wastage?

The 5S process is a methodology to avoid the 7 types of wastage Signup and view all the answers

What should be done with an item that is not needed or is obsolete?

Sell or throw it away Signup and view all the answers

Who is credited with the quote about the importance of the 5S culture?

Taiichi Ohno Signup and view all the answers

What is the purpose of involving Controlling in the evaluation process?

To assure the items staged for disposal are reviewed against the asset list Signup and view all the answers

What should be done with an item that is broken?

Repair or throw it away Signup and view all the answers

What is the 8th type of wastage?

Skills Signup and view all the answers

What does housekeeping refer to in the context of 5S?

Cleaning and organizing the workplace Signup and view all the answers

What is the purpose of storing items off-site or on an alternate server?

For items that are used once or twice a year Signup and view all the answers

What should be done with an item that is stored in the wrong location?

Move it to the correct location Signup and view all the answers

What is the deadline for disposing or relocating an item from the quarantine area if more time is required?

The following week Signup and view all the answers

What is the purpose of tagging items as red?

To identify unneeded items and excess items Signup and view all the answers

What is the main goal of standardizing tool board layout and composition?

To simplify the process of re-orienting workers when changing functions Signup and view all the answers

What is an essential step in evaluating the success of the Set in Order phase?

Verifying that items are put back on their designated place after use Signup and view all the answers

What is NOT a target of the Shine phase?

Reducing the noise level in the workplace Signup and view all the answers

What is NOT a benefit of standardizing the tool board layout and composition?

Improving workplace safety Signup and view all the answers

What is the main objective of the 'Shine' phase in 5S activities?

To remove dirt, grime, and dust from the workplace Signup and view all the answers

What is NOT a way to evaluate the success of the Set in Order phase?

Reducing the number of workers Signup and view all the answers

What is a benefit of keeping every tool, equipment, or machine in top condition?

Ensuring that equipment is always ready to be used Signup and view all the answers

What is NOT a target area of the Shine phase?

Office furniture Signup and view all the answers

What is the primary purpose of the signboard strategy?

To identify the names of work areas and equipment storage locations Signup and view all the answers

Which strategy is used to identify locations on floors and walkways?

Painting strategy Signup and view all the answers

What is the main benefit of using the signboard strategy?

It facilitates operations by placing frequently used items close to the point of use Signup and view all the answers

What is the purpose of amount indicators in the signboard strategy?

To show how many items should be stored in a location Signup and view all the answers

Which strategy is used to show clearly which materials or tools are used for which purpose?

Color coding strategy Signup and view all the answers

What is the main difference between the signboard strategy and the painting strategy?

The purpose of the signs Signup and view all the answers

What is the purpose of shadow boards?

To show which tools are stored where Signup and view all the answers

What is the first step in the signboard strategy?

Determine the location of the items Signup and view all the answers

What is the benefit of using the color coding strategy?

It helps to identify which materials or tools are used for which purpose Signup and view all the answers

What is the final step in the signboard strategy?

Make orderliness easy to maintain Signup and view all the answers

Study Notes

Introduction to Certified Lean Six Sigma

This course focuses on process-centric improvement using Lean, Six Sigma, and Process Management methodologies.
The course aims to equip students with a comprehensive understanding of various tools and methodologies.

5S Lean Tool

5S is a fundamental method of lean management and lean production.
The goal of 5S is to generate value without waste and promote continuous improvement for higher productivity.
5S is a management tool that creates commitment and ownership.

Benefits of 5S

5S is the backbone of world-class manufacturing.
It is a visual workplace and a fundamental platform for world-class manufacturing.
5S is a continuous process that develops simplified work environments and reduces waste while improving quality and safety.

7 Types of Wastage

5S is the base methodology to avoid the 7 types of wastage.
The 7 types of wastage are:
Wastage costs money, time, and nerves.
Skills are considered the 8th waste.

5S and TIMWOOD

5S addresses TIMWOOD, the 7 wastes.
TIMWOOD wastes are:

Housekeeping

Housekeeping involves removing unnecessary items, excess items, and items that are not needed.
Red-tagged items are evaluated, and their final location is decided.
Dispose or relocate items that are not needed.

Propose Actions for Red-Tagged Items

Decide actions for red-tagged items during evaluation.
Actions include:
- Transfer if needed elsewhere.
- Sell or throw away if not needed or obsolete.
- Repair or throw away if broken.
- Clean if dirty.
- Move to correct location if stored in the wrong location.

Rules of Thumb for Holding Times

How often an item is used determines how to store it.
Store items off-site or on an alternate server if used once or twice a year.
Store in the facility or on a shared folder if used once a month.
Store in the general area or on a PC if used once a week.
Store at point of use if used daily.

Decide How to Mark Location

Use signboards, painting, or color coding strategies to mark locations.
Signboards show what, where, and how many items are stored.
Painting strategy identifies locations on floors and walkways.
Color coding strategy shows which materials or tools are used for which purpose.

Shine Phase

The Shine phase emphasizes removing dirt, grime, and dust from the workplace.
The goal is to turn the workplace into a clean place where everyone will enjoy working.
Shine phase also targets keeping every tool, equipment, or machine in top condition, ready to be used.

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Description

Improve process performance and business outcomes using Lean Six Sigma methodologies and process management techniques. Learn to analyze and optimize processes for better results.