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Lean 6 Sigma questions

1. Give one example of service recovery.
2. Give one example of service guarantee.
3. What is "poke-yoke"? Give one example.
4. What is 5S framework? Give one example of each "S."
5. What are 7 basic types of wastes (mudas) in any process? Give example of each muda.
6. What are five steps (elements) of Lean Thinking as per the textbook?
7. You are a small manufacturing job-order workshop. You have found that your accident rate trend is increasing in recent months. How will you use a Kaizen event/approach to reduce accident rate?
8. What is "moment of truth"? Give one example.
9. What are two factors (consequences) that result from a service that is "high contact"?
10. State two reasons Just-in-time (JIT) requires employee involvement. Explain why.
11. State two reasons JIT implementation improves quality. Why?
12. What are two risks in JIT implementation?
13. What is a "non-value-adding" activity? Give one example.
14. Is continuous improvement (incremental improvement) same as BPR? Why or why not?
15. A copy machine was observed for 1200 hours. It had a downtime of 90 hours during this period. What is its Availability?

Solution Preview

1. Give one example of service recovery.
Poor service in a Cracker Barrel restaurant results in the meal being free and a coupon for a return visit.

2. Give one example of service guarantee.
Comcast installation is guaranteed to be on time, failure for the installer to show on time results in a $20 credit.

3. What is "poke-yoke"? Give one example.
Poke Yoke- mistake proofing. A file cabinet's drawers lock when one is pulled out to prevent other drawers from being opened resulting in the cabinet falling over.

4. What is 5S framework? Give one example of each "S."
Makes manufacturing more efficient by improving organization in the workplace (good housekeeping)
Seiri- reduce infrequently used material or tools
Seiton- reduce clutter, put things away so they can be easily retrieved
Seiso- cleanliness, keep work area/tools/supplies clean
Seiketsu- completion of the first 3 S's
Shitsuke- discipline, rewarding people who show devotion to the 5 S's

5. What are 7 basic types of wastes (mudas) in any process? Give example of each muda.
Inventory - maintain old inventory, taking up warehouse space
Over production - producing more goods than you can sell, results in clearance sales or excess inventory
Motion - lack of organization, too many movements in the production process
Waiting - employees who have to ...

Solution Summary

Addressing 15 points of the Lean 6 method

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