CLBB flashcards
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32 cards. Read the term and the definition here. The deck at the top of this page is optional.
- DPMO formula
- Defects per million opportunities equals defects divided by (units times opportunities per unit), multiplied by one million. It normalizes defect counts for comparison across processes.
- Six Sigma defect target
- Six Sigma aims for 3.4 defects per million opportunities, reflecting a process centered at a 1.5 sigma shift from specification limits.
- DMAIC vs DMADV
- DMAIC improves an existing process through Define, Measure, Analyze, Improve, Control. DMADV designs a new process or product through Define, Measure, Analyze, Design, Verify.
- Eight wastes
- Lean's eight wastes are defects, overproduction, waiting, non-utilized talent, transportation, inventory, motion, and extra processing. They represent non-value-adding activity.
- Rolled throughput yield
- RTY is the product of each process step's first-pass yield. If five steps each yield 95%, RTY is approximately 77%.
- Cost of poor quality
- COPQ includes internal failure, external failure, appraisal, and prevention costs. Prevention and appraisal are costs of good quality, not poor quality.
- Critical to quality
- CTQs translate voice-of-customer needs into measurable characteristics with defined specification limits. They drive what the project measures.
- Cp definition
- Cp equals (USL minus LSL) divided by six sigma. It measures potential capability and ignores whether the process is centered.
- Cpk definition
- Cpk is the minimum of (USL minus mean) and (mean minus LSL), each divided by three sigma. It accounts for centering and never exceeds Cp.
- Capability threshold
- A process is commonly considered capable at Cpk of 1.33 or greater, with 1.67 or greater often required for critical characteristics.
- OEE formula
- Overall equipment effectiveness equals Availability times Performance times Quality. World-class OEE is commonly cited at 85%.
- Takt time
- Takt time equals available production time divided by customer demand rate. It sets the pace a process must meet to satisfy demand.
- Little's Law
- Little's Law states that work-in-process equals throughput rate multiplied by flow time. It relates inventory, throughput, and cycle time in a process.
- Tuckman team stages
- Teams develop through forming, storming, norming, performing, and adjourning. Each stage has distinct leadership needs and team dynamics.
- RACI matrix
- RACI assigns Responsible, Accountable, Consulted, and Informed roles to tasks. Only one person should be accountable for each task.
- Team charter contents
- A team charter documents purpose, scope, sponsor, members, milestones, and decision authority. It aligns the team and prevents scope creep.
- Thomas-Kilmann conflict modes
- Five conflict-handling modes are competing, collaborating, compromising, avoiding, and accommodating. Choice depends on importance of outcome and relationship.
- SIPOC diagram
- SIPOC maps Suppliers, Inputs, Process, Outputs, and Customers at a high level. It defines process scope and boundaries for the project.
- Problem statement criteria
- A problem statement should be data-based, quantified, and free of cause or solution language. It states what is wrong and how much.
- SMART goal statement
- A SMART goal is specific, measurable, achievable, relevant, and time-bound. In Six Sigma it names the metric, baseline, target, and target date.
- Kano model categories
- Kano classifies requirements as must-be, performance, attractive, indifferent, or reverse. Must-be needs cause dissatisfaction if absent but do not delight when met.
- Gage R&R components
- Gage R&R partitions measurement variation into repeatability (equipment) and reproducibility (appraiser). Variation under 10% of tolerance is generally acceptable.
- Rational subgrouping
- Rational subgroups group items produced under similar conditions so within-subgroup variation reflects common causes only. This makes control chart limits meaningful.
- Type I and II errors
- Type I error rejects a true null hypothesis (alpha). Type II error fails to reject a false null (beta). Power equals one minus beta.
- ANOVA purpose
- ANOVA compares means of three or more groups. The F statistic is between-group variance divided by within-group variance.
- Chi-square test purpose
- The chi-square test of independence evaluates whether two categorical variables are associated. It compares observed counts to expected counts.
- Poka-yoke
- Poka-yoke is error proofing that prevents defects by design rather than detecting them by inspection. Examples include fixtures that make incorrect assembly impossible.
- FMEA risk priority number
- RPN equals Severity times Occurrence times Detection. Higher RPN failure modes are prioritized for corrective action.
- 5S method
- 5S consists of sort, set in order, shine, standardize, and sustain. It creates an organized, standardized workplace that supports flow and reduces waste.
- Control chart signals
- Points outside three-sigma control limits, runs of eight on one side, and trends signal special-cause variation. Control limits come from process data, not specifications.
- Attribute control charts
- p and np charts monitor proportion or number defective per subgroup. c and u charts monitor defect counts per unit.
- Control plan contents
- A control plan records the characteristic, specification, measurement method, sample size, frequency, and reaction plan. It sustains improvements after project closure.