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Lean 6 Sigma questions

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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?

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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

See Also This Related BrainMass Solution

Problem Measurement Document: Lean Six Sigma

See the attached file.

Submit a Problem Measurement Document which will demonstrate your ability to measure a problem situation using the Measure Phase of DMAIC.

* Differentiate the various relevant aspects of the situation and define the problem at the Blackbelt level using various tools of the Measure Phase.
* Organize the appropriate information into a coherent report.
o Download and use the Measurement Report Outline provided.
o Be sure to use Topic Headings that correspond to the major topics
* The report should contain all the necessary and sufficient aspects to completely measure the problem.
o Include copies of various Tools that were used
o Provide Discussion and explanation where appropriate and necessary
o Include sources of documentation
o Include examples of reports used to generate evidence and data

Measure phase of the project. Some of the questions that need to be answered in this phase are:

* What are the key metrics for this business process?
* Are metrics valid and reliable?
* Do we have adequate data on this process?
* How will I measure progress?
* How will I measure ultimate success?


1. Use the Process Flow Chart from the D Phase. Refine it and detail it as much as necessary.
2. Determine the key output variable - what is the Target Output that is the Key indicator of the Problem?
3. Determine what the input variables are that have effects on the output.
4. How do you count these variables? (Measurement is counting!!) Can you use time, distance, quantity, etc?
5. Develop a plan.
1. What is the period of time that you need to collect the data?
2. what are the sources of the data?
3. who is going to get the data and record it?
4. where and how will the data be recorded?
5. are you going to do a pilot study first?
6. Collect data according to the plan or do a pilot study
7. Perform preliminary analysis of the output data to determine process variation
8. Perform other analysis to validate and verify the data
9. Write the Measurement Report.

Required reading:

iSix Sigma, Six Sigma DMAIC Roadmap retrieved on Mar 16, 2010 from


iSix Sigma, Six Sigma DMAIC Reference retrieved on Mar 16, 2010 from


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