Keeping a Manufacturing Assembly Line Stable
Six Sigma – iSixSigma › Forums › General Forums › Tools & Templates › Keeping a Manufacturing Assembly Line Stable
- This topic has 9 replies, 1 voice, and was last updated 1 year, 1 month ago by
jshivani15.
- AuthorPosts
- March 24, 2016 at 11:39 am #55301
68rs327Participant@68rs327Include @68rs327 in your post and this person will
be notified via email.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.0March 24, 2016 at 1:37 pm #199509It 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!
1March 25, 2016 at 12:54 pm #199515
Chris SeiderParticipant@cseiderInclude @cseider in your post and this person will
be notified via email.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).
0March 25, 2016 at 1:05 pm #199517
68rs327Participant@68rs327Include @68rs327 in your post and this person will
be notified via email.Getting the supervisors involved has been an issue.
0March 28, 2016 at 10:35 am #199522When 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.0March 29, 2016 at 2:34 am #199523
MajkaGuest@majka20Include @majka20 in your post and this person will
be notified via email.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- 200March 29, 2016 at 9:44 am #199524
Katie BarryKeymaster@KatieBarryInclude @KatieBarry in your post and this person will
be notified via email.@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.
0March 29, 2016 at 11:15 am #199525
MajkaGuest@majka20Include @majka20 in your post and this person will
be notified via email.Yes, I got it, thank you and sorry for spam :)
0August 3, 2016 at 9:37 pm #199962
Rafael Sbeghen SeniseParticipant@rafaelseniseInclude @rafaelsenise in your post and this person will
be notified via email.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 productsQuestion 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 DMAICQuestion 6)Who among the following is a stakeholder in Six Sigma?
Rresponse: 4- All of the aboveQuestion 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- SuppliersQuestion 12)As the six sigma level decreases, the defect percentage
Rresponse: 2- IncreasesQuestion 13)Which of the following is a DFSS methodology?
Rresponse: 2- DMADVQuestion 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 BQuestion 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.
0December 6, 2019 at 8:04 am #244300
jshivani15Participant@jshivani15Include @jshivani15 in your post and this person will
be notified via email.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 year, 1 month ago by
jshivani15.
- This reply was modified 1 year, 1 month ago by
jshivani15.
0 - This reply was modified 1 year, 1 month ago by
- AuthorPosts
You must be logged in to reply to this topic.