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50 Cards in this Set
- Front
- Back
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Andon |
Production line light indication system |
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Heijunka |
Scheduling small batches of family processes together to improve throughout |
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Hoshin kanri |
Ensuring alignment between company strategy, management tactics, and operations actions |
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Jidoka |
Autonomation |
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Poka-yoke |
Mistake proofing |
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Theory of constraint steps (5) |
Identify the limiting process Exploit the process to maximum throughout Subordinate all processes to it Elevate the system (more of the same process, outsourcing, etc.) Repeat. |
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Value stream maps show (3) |
Flow of materials from suppliers supplier to customers customer. Production steps that have transform the product. Information flow required to support material flow and production. |
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Lean value stream |
Minimal storage in wip Minimal transmission energy in inventory Short resting times No unneeded steps All decisions and production based on demand |
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DMADV |
Define Measure Analyze Design Verify |
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IDOV |
Identify Design Optimize Verify |
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Six Sigma Scoping |
Must be large enough to control outputs (3-4 factors not enough) Must be specific Do not use separate projects for each symptom (Root Cause Analysis) Must be robust or antifragile |
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Design Considerations (13) |
Cost Manufacturability Testability Maintainability Robustness (mtbf = 1/failure rate) Usability Extended functionality Efficiency Performance Security Scalability Agility Compliance Safety |
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Process inputs (7) |
Man Materials Methods Mother nature Management Measurement system Machines |
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Benchmarking steps |
Flowchart current process Identify improvement areas Brainstorm ideas Investigate superior performance by others Develop application plans Pilot test ideas Initiate successful processes Repeat |
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Ideal design |
Maximizes value delivery at minimal cost. Link customer requirements to product features. Employ design tools that will result in totally new approaches. |
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Quality function delivery matrix areas |
Customer requirements Technical requirements Relationship matrix Customer comparison with competition Action notes Technical comparison with competition Target values Co relationships |
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Project charter contains |
Problem SMART statement; what needs improvement Purpose; goals and objectives Benefits; how the company will be better Scope; project boundaries Results; project success metrics |
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Risk analysis tools (4) |
SWOT matrix Risk priority number matrix (rpn matrix) FMEA Expected profit calculations |
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Risk analysis impact factors (8) |
Goals and objectives Planned schedule Identified resources Safety Producibility Serviceability Reliability Customer requirements |
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Project closure |
Review of project deliverables against the original charter to ensure expectations were met. |
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Activity network diagram |
Card style flow chart showing activities and times with beginning ending relationships. |
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Flowcharting (6) |
Define the process, title the document Establish boundary conditions Catalogue all activities that take place Sequence the activities Fill material and information arrows Review with all relevant parties |
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Force field analysis |
Two column listing of driving or restraining forces to a goal listed at the top.
Elimination of restraining forces should be prioritized. |
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Interrelationship diagram |
Clockwise listing of concerns with arrows pointing between them with direction indicating which influences the other more |
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8D phases |
Establish team Define problem Contain problem Root cause analysis Check corrective action plan Implement corrective action plan Adjust system to prevent recurrence Congratulate team |
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Sampling plan |
Check sheet or other document including points for inspectors to identify |
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Balanced scorecard |
Performance in: Finance Customer satisfaction Internal processes Learning Growth |
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Brainstorming |
Creation phase: As many ideas as possible. Do not share feedback during this phase. All ideas get written down.
Evaluation phase Separate from creation by 10+ minutes. |
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Nominal group technique |
If group has vocal few, have members separate and evaluate ideas as individuals. Results written. |
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Pictorial check sheet |
Image of analysis subject used to indicate locations of interest |
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Calibration |
Drift in average of absolute values |
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Stability |
Drift in absolute value over time |
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Repeatability |
Variation in measurement by the same person on the same equipment at the same time. Expressed in units of standard deviation |
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Reproducibility |
Variation from two or more appraisers, multiple times |
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Linearity |
How well measurement corresponds to a straight line between input setting limits |
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Binomial distribution |
Inspection value has 2 states, typically good or bad. Would plot probability of occurance per number of occurances. |
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Confidence interval |
Ave+/- z(s/sqrt(n)) |
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Poisson distribution |
Counts multiples per unit (defects per unit for example)
Plot could be probability of occurance over number of occurances. X is number of defects Lambda is n*p |
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Chi square distribution |
(DoF)*Var(s)/var(p) Plots ratio of two sets. |
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T distribution |
T=xave-mu/(s/sqrt(n)) Mean is zero. Symmetric about mean |
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F distribution |
Used to compare variance of two or more populations to determine if they are equal. |
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When to sample |
Random sampling for homogeneous lots Sequential sampling for destructive tests is when testing is expensive. Stratified sampling when lots at not homogenous. |
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Power |
% chance that alpha hypothesis is true |
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Multivari study |
Analyzes cyclical, positional, and temporal variation. 1. Select process and characteristic 2. Select manageable sample size 3. Record time and values in table format 4. Plot measured values as a function of time. 5. Connect time values to get vertical lines 6. Look for variation 7. Do additional studies to get better data. 8. Improve process and repeat. |
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Correlation |
Identifying how input x affects outcome y and scaling effects. |
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Causation |
Event A causes outcome B |
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Linear regression |
Best of fit line through all points.
Made by least squares method. Confidence level is 1-alpha |
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Data types and value |
Nominal<ordinal<interval<ratio |
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Histogram |
X axis buckets numerical distribution Y axis shows frequency of occurance |
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Control limits |
25+ samples Derived from process data |
