8 WASTES OF LEAN

1. Administering incorrect doses to patients

➢ Defects
2. Moving hospital patients from department to department
➢ Transportation
3. Waiting for responses from other departments
➢ Waiting
4. People searching for materials, tools or equipment
➢ Motion
5. Creation of meals that are not eaten or partially eaten
➢ Overproduction
6. Entering the same data in more than one place on a form or in a software application
➢ Extra Processing
7. Cabinets full of office supplies
➢ Inventory
8. People with advanced skills do routine work
➢ Non-utilized talent
9. Patients in waiting rooms
➢ Waiting
10. Extra report information
➢ Extra Processing
 QUIZ
1. Lean Six Sigma is only applicable to quality related initiatives.
➢ False
2. An existing assembly process of PCBs needs to be improved. What LSS approach is more
applicable?
➢ DMAIC
3. Lean originated in 1940s from Toyota and Six Sigma originated in 1980s from?
➢ Motorola
4. Quality is defined by
➢ Customers
5. What is Lean Six Sigma?
➢ All of the above
6. This is a waste due to a non conformity to a customer requirement or standard.
➢ Defect
7. These are process steps or elements that must be eliminated for organizations to be more
efficient and effective
➢ Non value adding activities
8. Lean focuses on waste elimination while Six Sigma focuses on
➢ Reducing Variation
9. DMADV stands for
➢ Define – measure -analyze – design – verify
10. These are LSS belt levels that are tool experts and helps GB project leaders in doing data
analysis and initiative quick wins.
➢ Yellow belt
 DEFINE PHASE
1. Project charter element that describes the importance of doing the project
➢ Business Case
2. There are benefits associated with the goals of closing the GAP
➢ TRUE
3. A tool used to see boundaries of the process on the onset of the project.
➢ SIPOC DIAGRAM
4. This is an activity that we do to close the gap between the current condition and target
condition
➢ Problem Solving
5. This is an activity that we do to create a new baseline or target.
➢ Improvement
6. These are types of problems that are recurring and solutions are not known yet.
➢ Significant
7. How many process steps are recommended in creating your SIPOC Diagram?
➢ 5-7
8. “Increasing rejection rate with an average of 5% vs target of 2% since WW20 to WW32
which is a gap of 3% due to Process X operators” is a correct problem statement.
➢ False
9. The Objective / Goal Statement must include the solution to the identified problem.
➢ False
10. What kind of metric is said to be the risk assessment metric for your project?
➢ Consequential
 Measure Phase
EXERCISE #5; EXERICSE #6 – Basic Statistics Using Minitab
1. Average fat
➢ 16.46
2. How many data points represent the mode in the % Fat data set?
➢ 2
3. Median % Fat is
➢ 16.40
4. Mode of % Fat data set is
➢ 16.3
5. Range of % Fat is
➢ 7.70
6. Average Energy Cost is
➢ 330.6
7. Median Energy Cost is greater than Mean Energy Cost
➢ False
8. Three (3) data points represent the Mode Energy Cost
➢ False
9. Standard deviation of Energy Cost is
➢ 154.2
10. What central tendency is not applicable in the Energy Cost data set?
➢ Mode
 Measure Phase

1. In a process map, an ellipse designates

➢ Start and stop point
2. Tool used to validate reliability of a data source.
➢ Measurement system analysis
3. Which of the following is NOT TRUE about measurement?
➢ Data collection is only conducted in Measure Phase of DMAIC
4. This give a common understanding of the how the word / term is being used in the context
of the project
➢ Operational Definition
5. Which does not belong to the group?
➢ Height
6. Measurement scale that gives us ordered units that have the same difference and has no
absolute zero
➢ Interval
7. These are measurements from a continuum scale.
➢ Continuous
8. Which does not belong to the group?
➢ Body temperature
9. Accuracy is to central tendency; Precision is to
➢ Dispersion
10. Preferred measure of central tendency when there is an outlier or unusual observation.
➢ Median
 ANALYZE

1. What is the Median Pulse Rate for Female and Male?

➢ 80 & 76
2. Which Activity is the most significant contributor of Pulse Rate?
➢ Moderate
3. What is the IQR of Pulse based on Ran (Yes or No)?
➢ 30 & 13.5
4. Is there a significant difference between the distribution of Pulse based on whether the
person is smoking or not smoking?
➢ No there is none
5. What possible relationship is there between Pulse and Height?
➢ Possible Negative Correlation
6. What possible relationship is there between Pulse and Weight?
➢ Possible Negative Correlation
7. Which type of activity has an outlier Pulse?
➢ Moderate
8. How many % of the Male subjects of the study has a Pulse Rate meeting the standard of
70 to 100 BPM?
➢ 75%
9. Which bin or interval has the highest number of frequencies for Pulse?
➢ 75 & 85
10. Which bin or interval has the highest number of frequencies for Pulse?
➢ 2
 ANALYZE PHASE

1. A tool used to discover potential things that could impact the output of the process you
are investigating.
➢ Fishbone Diagram
2. A graphical tool used to compare distribution of the data and the location of the central
tendency in terms of the median.
➢ Box plot
3. A tool that follows the 80-20 principle stating that 80% of the effect is accounted to 20%
of the factors.
➢ Pareto
4. Why-why analysis is strict to asking a minimum of asking 5 whys
➢ False
5. This is a measure of the spread or data distribution in a box plot.
➢ Inter quartile range
6. In Root Cause Analysis, this is the last major cause that we explore
➢ Man
7. Which does not belong to the group?
➢ Time series
8. Which is not a pattern that can be highlighted by a time series chart?
➢ Limits
9. High lead time is affected by high preparation time can be explained by a
➢ Positive correlation
10. A type of histogram that is caused by natural limits in the outcome of the process.
➢ Skewed
 IMPROVE PHASE QUIZ

1. This tool can help reduce bottlenecks due to human intervention.

➢ Cross Training
2. Tools deployed to facilitate prevention or correction of errors in the process by making
things obvious.
➢ Visual management
3. 5S can be done as stand alone improvement even outside Lean Six Sigma.
➢ True
4. Which among the following is not a variation of a standard work?
➢ SMED Worksheet
5. Arrange the following from good to best.
➢ Containment – Detection – Prevention
6. In a PICK Matrix, you will ________ solutions with high effort but with low impact.
➢ KILL
7. In a PICK Matrix, you will ________ solutions with low effort but with high impact.
➢ PROCEED
8. A guide on how to deploy the implementation of identified activities.
➢ IMPLEMENTATION PLAN
9. Set of tools that can aid in the evaluation and display of the results of the implemented
solution and improvement
➢ EVALUATION TOOLS
10. Which among the options given can be used for evaluation of effectiveness for
implemented improvement actions? Check all that applies.
➢ Box plot
 CONTROL PHASE

1. It is the distance allowed for common causes of variation from the mean.
➢ +/- 3sigma
2. Special test for assignable causes can be used to examine trends, cycles or shifts in the data
points.
➢ True
3. If you have a continuous data set and been able to collect a group size of 15, is X bar and
R the best choice of control chart?
➢ No
4. It is a document that you will go back if problems are recurring from the project that you
completed.
➢ Process Control Plan
5. Control charts are used to display the amount of variation present in a process.
➢ True
6. Based on the normal distribution, data should be
➢ randomly
7. An analyst decided to count the number of defective parts with varying sample size taken
daily. He should use what type of control chart?
➢ P
8. Which of the following does not belong to the group?
➢ IX – MR
9. If a product or service cannot perform its intended function, then it said that it
➢ is defective
 REVIEW QUIZ
1. Lean Six Sigma is only applicable to quality related initiatives.
➢ False
2. An existing assembly process of PCBs needs to be improved. What LSS approach is more
applicable?
➢ DMAIC
3. Lean originated in 1940s from Toyota and Six Sigma originated in 1980s from?
➢ Motorola
4. Quality is defined by
➢ Customers
5. This is a waste due to a non-conformity to a customer requirement or standard.
➢ Defect
6. Lean focuses on waste elimination while Six Sigma focuses on
➢ Reducing variation
7. These are LSS belt levels that are tool experts and helps GB project leaders in doing data
analysis and initiative quick wins.
➢ Yellow Belt
8. Project charter element that describes the importance of doing the project.
➢ Business Case
9. There are benefits associated with the goals of closing the GAP.
➢ True
10. A tool used to see boundaries of the process on the onset of the project.
➢ SIPOC Diagram
11. How many high levels process steps are recommended in creating your SIPOC Diagram?
➢ 5-7
12. "Increasing rejection rate with an average of 5% vs target of 2% since WW20 to WW32
which is a gap of 3% due to Process X operators" is correct.
➢ False
13. The Objective / Goal Statement must include the solution to the identified problem.
➢ False
14. What kind of metric is said to be the risk assessment metric for your project?
➢ Consequential
15. In a process map, an ellipse designates
➢ Start and stop point
16. Tool used to validate reliability of a data source.
➢ Measurement System Analysis
17. Which of the following is NOT TRUE about measurement?
➢ Data collection is only conducted in the Measure Phase of DMAIC.
18. A tool used to discover potential things that could impact the output of the process you
are investigating.
➢ Fishbone Diagram
19. A graphical tool used to compare distribution of the data and the location of the central
tendency in terms of the median.
➢ Box plot
20. A tool that follows the 80-20 principle stating that 80% of the effect is accounted to 20%
of the factors.
➢ Pareto chart
21. This tool can help reduce bottlenecks due to human intervention.
➢ Cross Training
22. Tools deployed to facilitate prevention or correction of errors in the process.
➢ Mistake proofing
23. 5S can be done as stand-alone improvement even outside Lean Six Sigma.
➢ True
24. It is the distance allowed for common causes of variation from the mean.
➢ +/- 3 sigma
25. Special test for assignable causes can be used to examine trends, cycles or shifts in the
data points.
➢ True
26. If you have a continuous data set and been able to collect a group size of 5, is X bar and
R the best choice of control chart?
➢ Yes
27. It is a document that you will go back if problems are recurring from the project that you
completed.
➢ Process Control Plan
28. An analyst decided to count the number of defective parts with varying sample size taken
daily. He should use what type of control chart?
➢ P
29. The temperature inside a facility is being monitored due to its effect to a critical process.
Every day, the analyst takes 5 random temperature samples and records it. Which control
chart would you advise him to be used?
➢ X Bar and R
30. If a product or service cannot perform its intended function, then it said that it
➢ is defective