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IENG 451 - Lecture 13

IENG 451 - Lecture 13. Exam Review: Six Sigma Philosophy Lectures 01 – 12. Exam: Materials & Timing. On-Campus Exam is at LAB time in this room Things to Bring: Mechanical Pencil(s) & Eraser Calculator Engineering Notebook Examination Process: Arrive between 12:55 PM and 1:00 PM

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IENG 451 - Lecture 13

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  1. IENG 451 - Lecture 13 Exam Review: Six Sigma Philosophy Lectures 01 – 12 IENG 451 Operational Strategies

  2. Exam: Materials & Timing • On-Campus Exam is at LAB time in this room • Things to Bring: • Mechanical Pencil(s) & Eraser • Calculator • Engineering Notebook • Examination Process: • Arrive between 12:55 PM and 1:00 PM • Grab test gear, leave pack at back of room • Sit in front of a fresh exam, start exam at 1:00 PM • Complete exam with best answers possible • Return exam by 2:50 PM (exam must be in folder at 2:52 PM) • Quietly grab pack and stow test gear (keep your notebook) • Enjoy the refreshing absence of exam questions IENG 451 Operational Strategies

  3. Exam: Format & Directions • Exam is 45 min. long, but may have 1 hr, 50 min. • Exam is 40 questions, and may consist of: • Multiple Choice • Short Calculations • Short Answer • Exam Directions: • Do NOT pull apart the exam booklet or answer sheet • Do NOT write in the exam booklet • Put ALL answers on exam answer sheet • Scratch paper is provided with the exam answer sheet • Choose the best answer • Make sure exam booklet is returned and answer sheet & scratch paper is in the folder by 2:52 PM IENG 451 Operational Strategies

  4. Exam: Coverage & Topics • Exam covers Lectures 02 – 12, and portions of Rowlands text as covered in classes / labs • Lecture 02 – DMAIC Problem Solving: • DMAIC acronym • Project Team Approach • Membership • Time frame • Kaizen Approach • Membership • Time frame • DMAIC process detail • Purpose • Outputs • Steps • Indicators for when to follow DMAIC process IENG 451 Operational Strategies

  5. Exam: Coverage & Topics • Lecture 03 – Ideation: • Brainstorming • Purpose • Process • “NO” Rules • Fishbone Diagrams • Purpose • Process (how to construct) • 4 Ms and an E • Affinity Diagrams • Purpose • Process • Use to focus thinking • Multi-Voting • Purpose • Process • Use to move team forward IENG 451 Operational Strategies

  6. Exam: Coverage & Topics • Lecture 04 – Quality Matters: • Definition • Fitness for Use or Reduction of Variability • Cost of (Poor) Quality • Myths • Cost per Good Part • Leverage: Savings & Productivity • Understanding Variation • Aspects of Process Variation • Independence and Central Limit Theorem • Normal Distribution • Converting to N(0,1) using z-statistic • Area under the Standard Normal curve • Yield or Defective Computations • Six Sigma • Motorola Six Sigma IENG 451 Operational Strategies

  7. Exam: Coverage & Topics • Lecture 05 – Process Tools: • Process Capability – Cp • Meaning & Computation: Two Sided v. One Sided • Relation to Process Fallout • Recommended Minimum Ratios • Process Capability – Cpk • Relationship with Cp • Meaning & Computation • Process Capability – Cpm • Meaning & Computation • SIPOC Diagrams • Acronym • Identifies the Whats • Keys (actions) for a SIPOC Diagram • Swim Lane Charts • Identifies the Whos • Construction of a Swim Lane Chart IENG 451 Operational Strategies

  8. Exam: Coverage & Topics • Lecture 06 – Process Tools: • Value Stream Maps • Relationship with SIPOC and Swim Lane Diagrams • Use: AS-IS and TO-BE • Creating a VSM • Construction Steps • Typical Symbols • Typical Data Box information • Value-Added Concept • What is Value-Added • What is Non-Value-Added • What is Business Non-Value-Added • Value-Analysis (Time-Value-Map) • Addition to the bottom of the VSM • Steps to creation / addition • Meaning and use of the NVA to VA ratio IENG 451 Operational Strategies

  9. Exam: Coverage & Topics • Lecture 07 – Voice of the Customer: • Voice of the Customer (VOC) & Data Gathering Methods • Relationship with Value & Types of Customers (perspectives) • VOC Data & Gathering Methods • Four Levels of Data • Sources of Data and Segmentation • General Requirements • Face-To-Face Interviews • Description & Uses • Mistakes to Avoid • Telephone Interviews • Description & Uses • Mistakes to Avoid • Surveys • Description & Uses • Mistakes to Avoid IENG 451 Operational Strategies

  10. Exam: Coverage & Topics • Lecture 08 – Voice of the Customer: • Focus Groups • Description & Uses • Mistakes to Avoid • Point-Of-Use Observations • Description & Uses • Mistakes to Avoid • Analyzing the VOC • Reducing Risks and Identifying Features • KANO Analysis • Purpose (outcomes) • Steps, Responses, and Matrix • Meanings: Dissatisfiers, Satisfiers, and Delighters • CTQs • Acronym • Steps to develop CTQs • Good CTQ Characteristics IENG 451 Operational Strategies

  11. Exam: Coverage & Topics • Lecture 09 – Data Collection: • Ishikawa’s Tools • Listing of the 7 Tools • Histogram • Two Purposes • Description & Construction • Pareto Chart • Description & Uses • Fishbone Diagram • Description & Uses • Defect Concentration Diagram • Description & Uses • Check List • Description & Uses • Scatter Plot • Description & Uses IENG 451 Operational Strategies

  12. Exam: Coverage & Topics • Lecture 10 – Data Collection: • Data Collection Planning • Two Kinds of Data • 10 Steps in a Data Collection Plan • Measurement Selection • Steps • Matrix Description & Construction • Stratification Factors • Steps • Diagram Description & Construction • Operational Definitions • Purpose • Steps • Sampling Concerns • Minimum Sample Size Calculation • Continuous Samples computations • Discrete Samples: Large & Small computations IENG 451 Operational Strategies

  13. Exam: Coverage & Topics • Lecture 10 – Data Collection: • Measurement System Analysis: Gage R & R • Variability in Measurements • Total Variation • Product Variability • Gage Variability • Assessing Gage Capability • Repeatability • Reproducability • Process • Total Variance Computation • Product Variance Computation • Precision to Tolerance Ratio computation & Rule of Thumb • X and R chart Method Interpretation IENG 451 Operational Strategies

  14. Exam: Coverage & Topics • Lecture 11 – Improvement Selection: • Improvement Idea Methods • Benchmarking • Sources for Data • Four Types of Benchmarking • Pros & Cons • Alignment with Management • Sources for Directions • Data for Financial Alignment • Economic Models for Justification • Identifying Cash Flows • NPW • EAW • Reviewing the Economic Models IENG 451 Operational Strategies

  15. Exam: Coverage & Topics • Lecture 12 – Improvement Selection: • Improvement Selection Criteria • CTQs • Triple Constraint • Other Criteria • Developing Criteria & the Down-Select Process • Questions that might help • Steps for Down-Select • Decision Matrix • Steps (Matrix Construction) • Concerns • Pairwise Ranking • Steps • Concerns • FMEA • Purpose & Stage Uses • Steps (Matrix Construction) IENG 451 Operational Strategies

  16. Questions & Issues • On-Campus exam is Thursday at LAB (providing a 2 hour exam period!) • Distance / On-line exam instructions were covered earlier in term (see Lecture 01) • E-mail instructor for ADA accommodations IENG 451 Operational Strategies

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