D469 Quality, Continuous Improvement, and Lean Six Sigma - Set 5 - Part 1

Correct Answer: Smoothing production levels to reduce variation

Heijunka is a Lean tool used to smooth production levels by leveling out the production schedule, reducing variation, and improving efficiency.

Correct Answer: The customer’s needs and expectations

Voice of the Customer (VOC) refers to gathering customer feedback to understand their needs and preferences, ensuring the process meets customer expectations.

Correct Answer: Manage workflow based on actual demand

Kanban is a visual tool that helps manage workflow by signaling when to produce or order materials based on actual customer demand.

Correct Answer: To identify and prioritize potential failure points in a process

FMEA is a structured approach used to identify potential failure modes in a process and prioritize them based on their severity and likelihood of occurrence.

Correct Answer: Improve processes through a structured, data-driven approach

DMAIC stands for Define, Measure, Analyze, Improve, and Control. It is a data-driven framework used to improve processes by addressing defects and variation.

Correct Answer: The output is a function of the inputs

In Six Sigma, "Y = f(X)" refers to the idea that the output (Y) of a process is determined by the inputs (X), emphasizing the importance of controlling inputs to achieve desired outputs.

Correct Answer: The rate at which a finished product needs to be completed to meet customer demand

Takt Time is the pace at which products must be produced to meet customer demand, helping align production with customer needs.

Correct Answer: Prevent mistakes before they occur

Poka-Yoke, or mistake-proofing, involves designing processes in such a way that errors are either impossible or immediately detectable.

Correct Answer: Collecting data to establish a baseline for process performance

The Measure phase of DMAIC involves gathering data on the current process to understand its performance and identify areas for improvement.

Correct Answer: Track the average of a process over time

An X-Bar chart is used to track the average performance of a process over time, helping to monitor process stability and variation.

Correct Answer: Identify the underlying causes of defects in a process

Root Cause Analysis (RCA) is a method used to identify the fundamental reasons for defects or issues in a process, allowing for targeted improvements.

Correct Answer: Monitor process variation and detect out-of-control conditions

Control Limits are used in Six Sigma to establish the acceptable range of variation in a process, helping to identify when the process is out of control.

Correct Answer: Cost of Poor Quality

COPQ refers to the costs associated with producing defective products, including rework, scrap, and customer dissatisfaction.

Correct Answer: Continuous process improvement

The PDCA cycle is a framework for continuous improvement that involves planning a change, implementing it, checking the results, and acting on the findings.

Correct Answer: The number of defects found per unit produced

Defects Per Unit (DPU) is a metric used to measure the number of defects that occur per unit produced, helping to quantify the overall quality of a process.

Correct Answer: Monitor process variation and identify when the process is out of control

A Control Chart is used to track process data over time and detect when the process is out of control by monitoring variation.

Correct Answer: Continuous improvement through small, incremental changes

Kaizen is a philosophy that focuses on continuous improvement through small, incremental changes that lead to long-term improvements.

Correct Answer: Identifying and defining the problem to be addressed

The Define phase involves clearly defining the problem or issue that needs to be addressed, as well as setting the goals for the improvement project.

Correct Answer: Comparing the process output to the specification limits

Process Capability is a measure of how well a process can produce output within the specified limits, indicating its ability to meet customer requirements.

Correct Answer: Monitor and control process variation using statistical methods

Statistical Process Control (SPC) uses statistical techniques to monitor and control process variation, helping to maintain process stability and quality.