Lean, Toc, Six Sigma

Front 1

Foundations of Operational Stability:
What is Standardized Work and where does it appear on the House of Performance?

Back 1

It is a concept that says:
oThere is one and only one BEST way to do the work.
oThen we document that best way.
oWe may improve it tomorrow.
oWe are staunchly committed to the best way today

-It is in the Foundation of the House of Performance
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Front 2

Foundations of Operational Stability:
When developing a new Standardized Work process, what are the (4) different requirements the new standard is judged against? In what order?

Back 2

-Safer (most important)
-Higher quality
-Faster
-Lower cost (least important)

Front 3

Foundations of Operational Stability:
Will we ever be done with continuously updating Standardized Work? Why?

Back 3

No. Because we continuously need to improve how we do business.

Front 4

Name all of the core concepts in the Foundation of Operational Stability in the House of Performance.

Back 4

1. Standardized Work
2. Robust Products and Processes
3. Preventive Maintenance
4. Kaizen
5. Early Supplier Involvement
6. PDCA-Scientific Method
7. Waste

Front 5

Foundations of Operational Stability:
What are the 3 basic building blocks to Operational Stability in the House of Performance?

Back 5

PDCA-Scientific Method
Waste Elimination
Visual Management

Front 6

Foundations of Operational Stability:
Why is a house analogy used in the House of Performance?

Back 6

Just as building a house, there is a sequence for how to implement each section of the House of Performance. If you starting building walls before you have a solid foundation with building blocks, you will have a horrible house.

oWe are actually building something.
oWe are building something physical
oWe are building something that will last
oWe are building something we are proud of
oWe use tools to maintain the house (all homes require maintenance)
oBut you will not see any of the tools when the house is built
oA house tends to fall down when it is not kept up.
oSo our desire: make our house a little stronger every day.

Front 7

Foundations of Operational Stability:
What is the order in which we implement the House of Performance?

Back 7

1. Foundation
2. JIT and BIQ Pillars simultaneously
oWhile you are doing both of these, you are teaching the people how to use the lean tools to make waste stand out and attack it.

Front 8

Foundations of Operational Stability:
What is the chief purpose of The House Of Performance?

Back 8

To make waste stand out.

Front 9

Foundations of Operational Stability:
What is PDCA and what does it stand for?

Back 9

•It is a daily, team-based problem solving method that uses the PDCA thinking steps and the scientific method.
-It is the 'find it-fix it' tool
- it is a simplification of the scientific method which is:
Plan:
-Describe a hypothesis
-Plan a change
Do:
Experiment to test the hypothesis
Check:
Check for improvements
Act:
Then adopt the new standard, if better.

Front 10

What is the goal of the House of Foundations of Operational Stability:
Performance and which are NOT the goals of House of Performance?

Back 10

Goal: to build a strong enterprise
Not the Goals:
olean
oheadcount reduction
oto implement tools

Front 11

Foundations of Operational Stability:
What is Preventive Maintenance and its purpose?

Back 11

It is basic blocking-and-tackling care for your key equipment and resources by your skilled maintenance professionals and people that know the equipment well.

It's purpose: to get critical equipment and resources (including people) up and available to you a high percentage of the time (i.e. 99%) before attempting advanced principles like one-piece flow.

Front 12

What is the key tenent of Foundations of Operational Stability:
Preventive Maintenance concerning employees who use the equipment?

Back 12

Operators of equipment volunteer to do basic preventive maintenance. This is the most effective method of reducing unplanned downtime.

Front 13

Foundations of Operational Stability:
What is the definition of Robust Products and Processes?

Back 13

All processes are repeatable and consistently produce high quality parts; all products are well designed and easy to build

Front 14

Foundations of Operational Stability:
What is Kaizen?

Back 14

Daily, incremental improvement.

Front 15

Foundations of Operational Stability:
How does the Kaizen process work?

Back 15

-Update standardized work documentation
-Kaizen
-Update standardized work documentation
-Repeat

Front 16

Foundations of Operational Stability:
What are the concepts of Early Supplier Movement?

Back 16

-Involve suppliers of critical components early; use their input and ideas to drive down costs and lead time.
-Suppliers are treated as partners and are also trained in the House of Performance methods.

Front 17

Foundations of Operational Stability:
What are the concepts of Waste Elimination?

Back 17

-Education: Every team member is taught what waste is
-Eyes for Waste: Every team member is given authority to creatively reduce waste
-Employees jobs are not in jeopardy; but waste is
-The enemy is waste

Front 18

Foundations of Operational Stability:
Who is responsible for identifying and attacking waste?

Back 18

-Everyone, especially the front-line workers since they have the best view of the problems
-If we have 100 employees, we must have 100 heat sinking missiles that blow up with a suggestion when they see waste.

Front 19

Foundations of Operational Stability:
What are the 8 different types of waste and what is the acronym used to remember them?

Back 19

D: Defects
O: Overproduction
W: Waiting
N: Non-utilized talent
T: Transportation
I: Inventory
M: Motion
E: Extra processing
Originally, the TPS writings cited 7 types of waste, but added Non-utilized talent

Front 20

Foundations of Operational Stability:
(8 types of waste)
Define a Defect as a source of waste

Back 20

-Any part not made, or service rendered, to the customer’s specifications the first time

-Just because we can rework something does not mean it is a good thing.

Front 21

Foundations of Operational Stability:
(8 types of waste)
What are the (4) major root causes of Defects as a source of waste?

Back 21

-Lack of process controls
-Poor quality of incoming materials from suppliers
-Inadequate operator training
-Poor work instructions

Front 22

Foundations of Operational Stability:
(8 types of waste)
Define Overproduction as a source of waste.

Back 22

oFaster than needed for the customer
oSooner than needed for the customer
oMore than needed for the customer
oTaichii Ohno, the father of Lean, says that overproduction is the worst type of waste since it leads to most of the other types of wastes

Front 23

Foundations of Operational Stability:
(8 types of waste)
Define Waiting as a source of waste.

Back 23

Time lost when people, material or machines are waiting

Front 24

Foundations of Operational Stability:
(8 types of waste)
What are the (6) major causes of Waiting as a source of waste

Back 24

-Unbalanced workload
-Equipment breakdowns
-Long setup times
-Poor material handling practices
-Waiting for decisions, authorization or information
-Unanswered emails or phone calls

Front 25

Foundations of Operational Stability:
(8 types of waste)
Define Non-Utilized Talent as a source of waste.

Back 25

Wasted potential for improvements results when people doing the work are not consulted for ideas on improving the methods of work

Front 26

Foundations of Operational Stability:
(8 types of waste)
What are the (2) major root causes to Non-Utilized Talent as a source of waste.

Back 26

-Old guard thinking (that's the way we've always done it here, politics, business culture)
-Low or no investment in training

Front 27

Foundations of Operational Stability:
(8 types of waste)
Define Transportation as a source of waste.

Back 27

Transportation of parts and materials around a facility

Front 28

Foundations of Operational Stability:
(8 types of waste)
What are the (3) major root causes of Transportation as a source of waste and what tool can we use to attack it?

Back 28

-Poor shop/plant layout
-Large batch sizes
-Large storage areas

oUse a Spaghetti Chart to see how far the objects move around

Front 29

Foundations of Operational Stability:
(8 types of waste)
Define Inventory as a source of waste.

Back 29

-Any material in excess of the one piece requirement for the next step in the product.
-Everything is considered inventory unless it is being worked on right now

Front 30

Foundations of Operational Stability:
(8 types of waste)
What are the (3) types of Inventory as a source of waste?

Back 30

-Raw materials
-Work-in-process
-Finished goods

Front 31

Foundations of Operational Stability:
(8 types of waste)
What are the (2) major root causes of Inventory as a source of waste?

Back 31

-Inventory held “just-in-case” problems arise
-Unreliable shipments by suppliers

Front 32

Foundations of Operational Stability:
(8 types of waste)
Define Motion as a source of waste.

Back 32

oMovement of people or machines that does not add value to product

Front 33

Foundations of Operational Stability:
(8 types of waste)
What is the difference between Motion and Transportation as two different sources of waste?

Back 33

-Motion relates to people and ergonomics while Transportation relates to inventory and stuff.
-If a worker’s body is physically moving, this is motion.

Front 34

Foundations of Operational Stability:
(8 types of waste)
What are the (3) major root causes to Motion as a source of waste?

Back 34

-Poor shop/plant or workstation layout
-Poor workplace organization and housekeeping
-Sorting/looking for items

Front 35

Foundations of Operational Stability:
(8 types of waste)
Define Extra-Processing as a source of waste.

Back 35

Doing more than minimum required to transform material into an acceptable product.

Front 36

Foundations of Operational Stability:
(8 types of waste)
Why is Extra-Processing such a bad type of waste to have?

Back 36

-Because this is normally done by workers who have the best intentions at heart.
-Everyone must be willing to question everything we do to verify it is necessary.

Front 37

Foundations of Operational Stability:
(8 types of waste)
What are the (3) most common root causes of Extra-Processing as a source of waste?

Back 37

-Accommodate perceived customer needs
-Redundant approvals/inspections required
-Unnecessary reports produced

Front 38

Foundations of Operational Stability:
(8 types of waste)
Name (3) common examples of Extra-Processing as a source of waste.

Back 38

-Duplication
-Rework
-Engineering changes

Front 39

Foundations of Operational Stability:
Define the concept of Visual Management

Back 39

-We attempt to make the workplace so visual that anyone can walk into a workplace and visually understand the current situation
-Visual management beats nagging people every day to do or not to do something.

Front 40

Foundations of Operational Stability:
Provide at least (1) example of Visual Management.

Back 40

-paint outlines around a small area near final assembly with a line on the back wall stating “stack only this high”
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