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Keeping a Manufacturing Assembly Line Stable

Six Sigma – iSixSigma Forums General Forums Tools & Templates Keeping a Manufacturing Assembly Line Stable

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  • #55301

    68rs327
    Participant

    I work in the lean group of my company which is an automotive supplier. My group focuses on process improvement, scrap reductions, output improvements, reducing cycle times, line balance, etc.
    My question is: When my group goes to the production lines we make a ton of improvements, increase output, reduce scrap, improve ergonomics, etc. But when we leave the production line and go to the next production line to improve, we see the previous lines production start to go down within 2-3 weeks after my group leaving.
    Question: How does my company sustain the production after my group starts to work on another production line in the factory?
    It seems like once my lean group leaves and moves to the next lines, focus is lost and all the focus is on the current line we are working on.
    My company has my group focus on “Fire Fighting” and once the fire is out, we move to the next hot line, problem is.. we are making full circle and right back to the same lines in a few months.

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    #199509

    JB
    Participant

    It sounds like the reason performance is dropping is because “the lean team is making the improvements”. So, when the lean team leaves, the performance leaves.

    I’d suggest you work on coaching the folks who normally run the lines how to do what your doing, why your doing it, why the changes your making work. Much of being a lean leader is developing the improvement skills of others – that needs to be a priority. Do you implement standard work and leader standard work? That must be in place to maintain performance.

    Another suggestion would be to implement accountability boards for the managers to track and manage staff to be disciplined in the operation of the line.

    Good luck!

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    #199515

    Chris Seider
    Participant

    Perfect example of Hawthorne effect?

    Maybe the Lean group needs to better improvements with the process supervision and participants–are the controls being sustained (look at control phase of DMAIC).

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    #199517

    68rs327
    Participant

    Getting the supervisors involved has been an issue.

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    #199522

    When you are making a lean improvement think to:
    1 Human factors.
    2 Technical factors.
    3 Communication.
    In your case is a problem of Human factors and Communication. I use to buildup many groups based on Nonverbal Communication because, verbal communication is just 6% of our entire communication and if we have errors and we are not aware about the other type of communication. How long something is not define can’t be communicate but this thing will influence our results.

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    #199523

    Majka
    Guest

    PLEASE COULD YOU HELP ME ?

    Which of the following is an effect of Six Sigma implementation?
    1- Delays in shipment of products
    2- Decrease in cost and quality
    3- Reduction in production of defective products
    4- Decreased customer retention
    Which of the following assertions is true with regard to the Six-sigma approach?
    1- It is a factual-data based methodology.
    2- It is only used to bring about improvements in manufacturing processes.
    3- It aims at bringing down defects to 13.4 per million opportunities.
    4- Its main objective is to make the organization as lean as possible
    DMADV refers to
    1- Define, Measure, Analyze, Design and Validate
    2- Design, Measure, Analyze, Define and Validate
    3- Define, Modify, Analyze, Design and Validate
    4- Define, Measure, Analyze, Demonstrate, Verify
    ‘Lessons learned’ is an input for
    1- Analyze
    2- Improve
    3- Control
    4- None of the above
    DMADV used
    1- To improve the existing product or process
    2- When the existing product or process does not meet the level of customer specification or Six Sigma level even after optimization with or without using DMAIC
    3- To track the existing process performance
    4- None of the above
    Who among the following is a stakeholder in Six Sigma?
    1- Customer
    2- Supplier
    3- End user
    4- All of the above
    Specification limits are defined by
    1- Process data
    2- The customer
    3- The Master Black Belt
    4- The supplier
    Project CTQ (Y) Defect Definition
    Daily water consumption Any day water consumption > 15.6 unit
    What is the USL?
    1- 15.7
    2- 15.6
    3- 15.5
    4- None of the above
    Suppose you have the following information:
    Target = 23, specification limits = ± 3
    Average = 23, standard deviation = 0.6
    The process is a …………. sigma process.
    1- 3
    2- 4
    3- 5
    4- 6
    Identify the basic difference between DMAIC and DMADV.
    1- DMADV – Design of new products or improvement in existing products; DMAIC – Improvement in an existing process
    2- DMADV – Improvement in an existing process
    3- DMAIC – Design of new products or improvement in existing products; DMADV and DMAIC both are same
    4- None of the above
    Which of the following stakeholders is responsible for providing inputs to the process?
    1- Customers
    2- End users
    3- Suppliers
    4- Employees
    As the six sigma level decreases, the defect percentage
    1- Decreases
    2- Increases
    3- Remains constant
    4- May increase or decrease
    Which of the following is a DFSS methodology?
    1- DMAIC
    2- DMADV
    3- SIPOC
    4- COPQ
    Two variables A and B are plotted in a Scatter diagram as shown below.
    Link of the image: http://s8.postimg.org/o47ueejj9/image.png
    Choose the best possible option from the list.
    1- There is a strong positive linear relationship between A and B
    2- There is a weak negative linear relationship between A and B
    3- There is a strong negative linear relationship between A and B
    4- There does not exist any linear relationship between A and B
    A control chart is drawn for a process with a sample size of 20. How many special causes of variation are there?
    Link of the image: http://s22.postimg.org/hxlayg34h/image.png
    1- 0
    2- 1
    3- 10
    4- 20

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    #199524

    Katie Barry
    Keymaster

    @majka20 Although the iSixSigma audience is willing to help, they are not here to do your homework.

    Did you search our site? You should be able to find these answers with just a few clicks.

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    #199525

    Majka
    Guest

    Yes, I got it, thank you and sorry for spam :)

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    #199962

    Rafael Sbeghen Senise
    Participant

    Hey @majka20 these questions can be quite confusing some times. I had to read a few times to make sure it’s the correct answer. I suggest you contact a teacher to clarify your issues with the task or talk to the person that send it to you. I answered most of them. Now you have a new fresh start, I hope it still helps you….good luck

    Question 1) Which of the following is an effect of Six Sigma implementation?
    Rresponse: 3- Reduction in production of defective products

    Question 2) Which of the following assertions is true with regard to the Six-sigma approach?
    Rresponse: 1- It is a factual-data based methodology.

    Question 3) DMADV refers to
    Rresponse: 1- Define, Measure, Analyze, Design and Validate

    ** The right answer should be ”Verify” and not ”Validate” – Verify the design performance and ability to meet customer needs, but looking at the other answers, I’m pretty sure this is the most correct one).

    Question 4)Lessons learned’ is an input for
    Rresponse: 3- Control

    Question 5)DMADV used
    Rresponse: 2- When the existing product or process does not meet the level of customer specification or Six Sigma level even after optimization with or without using DMAIC

    Question 6)Who among the following is a stakeholder in Six Sigma?
    Rresponse: 4- All of the above

    Question 7)Specification limits are defined by
    Rresponse: 2- The customer

    **Most of the time the customer set’s up the specification limits, but some times it also can be defined by the The Master Black Belt.

    Question8)Project CTQ (Y) Defect Definition Daily water consumption Any day water consumption > 15.6 unit, What is the USL?
    Rresponse: You will need to do some math here.

    **Not feeling comfortable doing right now, sorry :(

    Question9)Suppose you have the following information: Target = 23, specification limits = ± 3 Average = 23, standard deviation = 0.6 The process is a …………. sigma process.
    Rresponse: Same as here.

    ** Take a look at this site, it should help you: https://www.qimacros.com/process-capability-analysis/cp-cpk-formula/

    Question10)Identify the basic difference between DMAIC and DMADV.
    Rresponse: 4- None of the above

    Question 11)Which of the following stakeholders is responsible for providing inputs to the process?
    Rresponse: 3- Suppliers

    Question 12)As the six sigma level decreases, the defect percentage
    Rresponse: 2- Increases

    Question 13)Which of the following is a DFSS methodology?
    Rresponse: 2- DMADV

    Question 14)Two variables A and B are plotted in a Scatter diagram as shown below.
    Rresponse: 2- There is a weak negative linear relationship between A and B

    Question 15)A control chart is drawn for a process with a sample size of 20. How many special causes of variation are there?
    Rresponse: 2- 1

    **only had one discrepancy, see graph.

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    #244300

    jshivani15
    Participant

    Hey @majka20

    I hope all these questions were asked from VMEdu site for Yellow Belt SixSigma Course. Did you receive the certificate after completing the test?

    • This reply was modified 1 month, 1 week ago by jshivani15.
    • This reply was modified 1 month, 1 week ago by jshivani15.
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