PRATHYUSHA ENGINEERING COLLEGE

DEPARTMENT OF MECHANICAL ENGINEERING

CME347 LEAN MANUFACTURING

UNIT 1 BASICS OF 6 SIGMA

Introduction to 6 Sigma, basic tools of six sigma like problem solving approach,
standard deviation, normal distribution, various sigma levels with some examples,
value for the enterprise, Variation, and sources of variation, Mean and moving the
mean, Various quality costs, cost of poor quality

PART A

1. What is SixSigma

Six Sigma is a set of methodologies and tools used to improve business processes by
reducing defects and errors, minimizing variation, and increasing quality and
efficiency. The goal of Six Sigma is to achieve a level of quality that is nearly
perfect, with only 3.4 defects per million opportunities.

2. What is SixSigma tools

Six Sigma tools are defined as the problem-solving tools used to support Six Sigma
and other process improvement efforts. The Six Sigma expert uses qualitative and
quantitative techniques to drive process improvement.

3. What are 5 Whys in Six Sigma

"5 Whys," is a guided team exercise for identifying the root cause of a problem. Five
Whys is used in the "analyze" phase of the Six Sigma DMAIC (define, measure,
analyze, improve, control) methodology.

4. What is Six Sigma and its types?

The Six Sigma certification has five levels as White Belt, Yellow Belt, Green Belt,
Black Belt, Master Black Belt. Six Sigma certification helps you to increase your
value to your clients and company.

5. What is the objective of Six Sigma?

The main goal of any Six Sigma implementation is quality improvement. The term
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 originally comes from the sigma rating used to statistically rate manufacturing
processes in engineering. A six sigma process occurs when no defects are expected in
99.99966% of all chances to produce them.

6.
What is standard deviation and mean example?
σ = √(∑x−x̄)2 /n) Now, let's take an example for a better understanding of 3, 2, 5, and
6. As stated above, using the formula for calculating the mean, it'll be calculated as
16/4 =4. The squared differences from average mean = (4-3)2+(2-4)2 +(5-4)2 +(6-
4)2= 10
7.
What is normal distribution and its application?
The Normal Distribution defines a probability density function f(x) for the
continuous random variable X considered in the system. It is basically a function
whose integral across an interval (say x to x + dx) gives the probability of the random
variable X taking the values between x and x + dx.
8.
What are the different levels of sigma?
White Belt
Yellow Belt
Green Belt.
Black Belt.
Master Black Belt.
Champion.
9. What is the formula for the value of enterprise?
Enterprise value (EV), total enterprise value (TEV), or firm value (FV) is an
economic measure reflecting the market value of a business (i.e. as distinct from
market price). It is a sum of claims by all claimants: creditors (secured and
unsecured) and shareholders
10. What is variation in Lean?
Variation is the term used to describe the consistency of a processes outputs.
Reducing variation is one of the most important objectives in Lean and Six Sigma.
The reduction of variation improves sigma rating and creates more stable processes
that can be improved upon.
11. What causes variation in Six Sigma?
Common cause variation – All processes have common cause variation. This
variation, also known as noise, is a normal part of any process. ...
Special cause variation – This variation is not normal to the process. It is the result of
exceptions in the process environment.
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12. What is the moving mean method?
Moving averages method is used in statistics to analyze data points, which are
calculated by averaging several subsets of a larger dataset. A moving average is a
measure of how well a piece of work is doing over a given period of time. The
moving average method is a popular stock indicator in technical analysis (MA).
13. What is the difference between moving average and mean?
In statistics, a moving average (rolling average or running average) is a calculation to
analyze data points by creating a series of averages of different selections of the full
data set. It is also called a moving mean (MM) or rolling mean and is a type of finite
impulse response filter.
14. What are the 4 types of quality costs?
The four major types of quality costs are prevention, appraisal, internal failure, and
external failure. Prevention costs are the costs created from the effort to reduce poor
quality.
15. What are the 4 costs of poor quality?
The cost of quality can be divided into four categories: prevention cost, appraisal
cost, internal failure cost, and external failure cost.
16. What is the Cost of Quality in Six Sigma?
The Cost of Quality is a method used by organizations to determine the amount of
resources required for good quality. It is simply the cost of producing quality
products and services. The cost of quality can be described as the sum of both good
quality and poor quality.
17. What is Cost of Poor Quality (COPQ)
Cost of Poor Quality (COPQ) is the cost associated with producing poor-quality
products or services for the customer. In other words, it is the total financial losses
incurred by the company due to errors and subpar work. For example, scrap, rework,
repair, and warranty failure all add to the cost of poor quality.
18. What are QC techniques?
Quality control refers to a company's methods for assessing product quality and, if
necessary, improving it. There are various ways to perform quality control,
including benchmarking, examining manufacturing procedures, and testing products.
All of this is done to keep track of significant product differences.
19. What are the two goals of Six Sigma?
As for goals, Six Sigma seeks to: Find and eliminate causes of defects and errors.
Reduce cycle times and cost of operations. Improve productivity.
20. What are the benefits of Six Sigma?
you will decrease waste. Six Sigma ideology is aimed to help you and your company
optimize processes to decrease your total waste. ...
You will increase efficiency

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 You will reduce errors
You will reduce your company's legal risk
You can apply it to any industry
You will make more money.
PART B

1. Discuss briefly about Six sigma tools.

2. Discuss briefly about Six Sigma's Value of Customer and a Market Driven Enterprise

3. Explain briefly about the reasons to attend Costs of Poor Quality and good quality.

4. Discuss briefly about Standard Deviation and Normal Distribution in Six Sigma
5. Explain briefly about Principles of Six Sigma and objectives of six sigma
6. Explain briefly about types of Variation

7. Discuss how to construct Moving Average Chart

8. Discuss aboutVarious quality costs.

9. Explain about various sigma levels with some examples.

10. Discuss how to value for the enterprise.

UNIT 2 INTRODUCTION TO LEAN MANUFACTURING TOOLS
Process Capability Indices, Cause and Effect diagram, Control Charts, Introduction to
FMEA, APQP, PPAP. 3 foundational 6 Sigma methodologies: DMAIC, DMEDI, and
Process Management DMEDI for process creation, DMAIC for process improvement
and PDCA for sustaining improvements.

PART A

1. Construct a Cause-and-Effect Diagram

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2. Discuss the purpose of PPAP

The purpose of the PPAP is to ensure that the customer's design has been understood
by the supplier and to prove that the supplier is capable of producing parts that meet
all the requirements consistently.

3. Discuss about 5 phases of PPAP

1. Plan and Define Program

2. Product Design and Development Verification
3. Process Design and Development Verification
4. Product and Process Validation and Production Feedback
5. Launch, Assessment & Corrective Action

4. Explain about 3 foundational 6 Sigma methodologies

DMAIC, DMEDI, and Process Management

5. What are the benefits of APQP?

Improved product quality

Enhanced customer satisfaction

Increased efficiency

Reduced costs

Improved supplier relations

Better risk management

Improved process control

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6. Discuss about control chart.
The control chart is a graph used to study how a process changes over time. Data are
plotted in time order. A control chart always has a central line for the average, an
upper line for the upper control limit, and a lower line for the lower control limit.
7. Write the benefits of control charts
Understand the variations that are always present in processes. ...
See when something is going wrong or may go wrong. ...
Notice patterns within plotted points. ...
Predict future performance.
Generate new ideas for improving quality based on your analysis.
8. What is PDCA Cycle?
PDCA (Plan-Do-Check-Act) is an iterative, four-stage approach for continually
improving processes, products or services, and for resolving problems. It involves
systematically testing possible solutions, assessing the results, and implementing the
ones that have shown to work.
9. Define APQP
APQP stands for Advanced Product Quality Planning. It is a methodology that
originated in the automotive industry to ensure the development and production of
high-quality products that meet customer requirements and expectations.
10. What is Process Capability Indices?
he process capability index (Cp) is a dimensionless parameter that indirectly
measures how well the process meets specifications, and the higher its value, the
better the process can meet the requirements [41,44].
11. Discuss about the benefits of cause and effect diagram
Helps determine root causes
• Encourages group participation
• Uses an orderly, easy-to-read format
• Indicates possible causes of variation
• Increases process knowledge
• Identifies areas for collecting data
12. What is difference between PPAP and APQP?
APQP is a process that happens during the product development lifecycle to facilitate
transparent communication and feedback throughout the supply chain. This process
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 allows suppliers to detect errors early on, incorporate customer feedback, and deliver
high quality products. PPAP is an output of APQP.
13. What are the 5 levels of PPAP?
Level 1: Part Submission Warrant (PSW) only submitted to the customer. Level 2:
PSW with product samples and limited supporting data. Level 3: PSW with product
samples and complete supporting data. Level 4: PSW and other requirements as
defined by the customer.
14. What are the 18 elements of PPAP?
 Design Documentation
 Engineering Change Documentation
 Customer Engineering Approval
 Design Failure Mode and Effect Analysis (DFMEA)
 Process Flow Diagram
 Process Failure Mode and Effects Analysis (PFMEA)
 Control Plan
 Measurement System Analysis Studies

15. What are the 5 steps of the FMEA process?

 Step 1: Determine What Needs to be Addressed. ...
 Step 2: Create a Cross-Functional FMEA Team. ...
 Step 3: Lay Down the Process, System, or Steps. ...
 Step 4: Analyze Each Step and Determine Problem Areas. ...
 Step 5: Select Which Issues to Prioritize. ...
 Step 6: Implement the Changes.
16. What is the formula for FMEA?
The information inputted into an FMEA is calculated, and the output is a Risk
Priority Number (RPN). The RPN is calculated by multiplying the severity times the
occurrence times the detection (RPN = Severity x Occurrence x Detection) of each
recognized failure
17. What are the 5 core tools?
 Advanced Product Quality Planning (APQP)
 Failure Mode and Effects Analysis (FMEA)
 Measurement Systems Analysis (MSA)
 Statistical Process Control (SPC)
 Product Part Approval Process (PPAP)

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18. Is FMEA part of DMAIC?
Failure Modes and Effects Analysis (FMEA) gives project teams a framework to
identify potential process failures and to estimate how the failure will affect the
customer. Project teams use FMEA in the Analyze stage of DMAIC. It helps them
spot tasks or product features that might experience high rates of failure.
19. Is DMAIC the same as Kaizen?
Kaizen™ and DMAIC are both business approaches with Kaizen™ being similar to
Lean methodology and DMAIC similar to Six Sigma.
20. Why is the PDCA cycle good for continuously improving?
Because of the continuous approach of PDCA, organizations can use this model to
gather relevant information before considering whether to progress with a plan or
make improvements. This data-driven approach provides a ground basis for
organizations' continuous improvement of processes, products, services, and people.
PART B
1. Explain briefly about Process Capability & Performance.
2. Discuss briefly about DMAIC

3. Discuss briefly about DMEDI

4. Discuss briefly about control charts

5. Discuss briefly about 18 elements of PPAP

6. Explain briefly about APQP and PDCA Cycle

7. Elaborate DMAIC approach for process capability improvement an engine crankshaft
manufacturing process
8. Explain briefly about how DMAIC for process improvement .

9. Explain about PDCA and discuss PDCA for sustaining improvements.

10. Discuss about 3 foundational 6 Sigma methodologies.

UNIT 3 DEEPER UNDERSTADING METHODOLOGIES

What is a process, Why Process management, Keys to process management,
Difference between process management and 6 Sigma, Introduction to Deming cycle,
PDCA, DMAIC and continuous improvement, DMEDI for creation process, DMAIC
Vs DMEDI with examples, Introduction to Toyota Production System, Six Sigma
and Production System integration.

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 PART A
1. What is 6 sigma in production?

Six Sigma identifies and removes defect-causing elements along with reducing the
changeability of the business and manufacturing processes to improve the quality of
outputs from a manufacturing process. In this methodology, an organization follows a
defined set of steps to quantify the targeted value of the project.

2. How do you apply Six Sigma in a production line?

These are:
1. Define the Project — This is usually a problem to be solved. ...
2. Measure – Collect data about the current system or process.
3. Analyze the Data — To find the root cause of the error.
4. Improve – Design and implement changes that will eliminate the error.

3. What is Lean Six Sigma and related production principles?

What Are the 5 Principles of Lean Six Sigma? Define, measure, analyze, improve,
and control are the five principles and phases of Lean Six Sigma. They're the steps
practitioners take to create more efficient processes and a workplace culture that's
focused on continuous improvement.

4. What is the definition of a process in Six Sigma?

A process is an organized group of related activities that work together to transform
one or more kinds of input into outputs that are of value to the customers. In other
words, a process is an activity or group of activities that takes the inputs, adds value,
and provides outputs to internal or external customers
5. How do you define a process?

A process is a series of steps and decisions involved in the way work is

completed.

6. What is a process and its types?

Process refers to an activity system that uses resources to transform input

elements into output elements. It describes the “what to do” in a predefined
order. Transversal by nature, it involves several businesses and transforms data
and/or materials to create added value.

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7. What are the 4 sections of a process?

A process has four sections, namely, text, data, heap, and stack.

8. What are the 3 key elements of process?

The three key elements of a process are:

 Efficiency – Making the most of time and resources during the process.
 Effectiveness – Ensuring the result of the process matches the objective.
 Scalability – Developing a process that can handle anticipated volume within the
constraints of available resources.
9. What are the main elements of a process?

The key elements of a business process are:

 Inputs and outputs.
 The sequence of steps or tasks performed.
The roles and responsibilities of individuals involved in the process.
 Performance measures or KPIs (key performance indicators) that track the success of
the process.
10. Why do we need process management?

More than creating seamless workflows, it enables all aspects of business operations
to run at an optimal pace. With business processes systematically implemented, you
reduce time wasted on repetitive tasks and minimize errors due to human
inefficiency.
PART B
1. Discuss the types of processes and Explain about process management strategies

2. Explain DMEDI for creation process with an example.

3. Discuss about PDCA cycle.

4. Discuss different stages of DMEDI and Explain the benefits of DMEDI

5. Discuss the principles of Toyota Production System.

6. Explain about push system and pull system

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7. Discuss briefly about JIT with Benefits and Drawbacks of JIT

8. Explain briefly about Deming cycle.

9. Discuss the functions of process management.

10. Difference between process management and 6 Sigma with examples.

UNIT 4 LEAN ELEMENTS

Introduction to Lean Concepts like In-Built Quality, Concept of Right Part at the
Right Time, Lead Time reduction, Optimum utilization of Capital, Optimum
utilization of People. Understanding the Zero-defect concept and Metrics, Focus on
Human Resources, Quality, Delivery, Cost. Building Zero defect capabilities,
Cultural and Organizational aspects

1. What is lead time.

Lead time describes the amount of time it takes to complete a specific process. In
business, lead time is often used to describe the amount of time it takes to process an
order, manufacture a product, delivery a good, or a combination of these processes.

2. Distinguish between Reactive and Proactive Quality Management

Reactive management is when leaders respond to crises and issues as they arise.
Proactive management means anticipating needs and challenges so that you and your
team are prepared to overcome them.

3. Explain the four elements of zero defects.

" The definition of quality is conformance to requirements"

"The system of quality is prevention"
"The performance standard is Zero Defects"
" The measurement of quality is the price of nonconformance"

4. Explain the main importance of human resources

HR plays a key role in developing, reinforcing and changing the culture of an
organisation. Pay, performance management, training and development, recruitment
and onboarding and reinforcing the values of the business are all essential elements
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 of business culture covered by HR.

5. Discuss the 4 types of human resource.

 Recruitment and Staffing. Staffing and recruiting cannot exist without each other, but
they are not the same. ...
 Employee Relations. ...
 Learning and Development. ...
 Performance Management. ...
 Company Culture.

6. What are the 4 steps of human resources?

Human resources planning ensures the best fit between employees and jobs while
avoiding manpower shortages or surpluses. There are four key steps to the HRP
process. They include analyzing present labor supply, forecasting labor demand,
balancing projected labor demand with supply, and supporting organizational goals.

7. What are the 4 types and 5 main areas of HR?

Human Resources manages 5 main duties: talent management, compensation and

employee benefits, training and development, compliance, and workplace safety. An
HR department can help provide organizational structure and the ability to meet
business needs by effectively managing the employee lifecycle.

8. What is the application of zero defects?

Zero defects theory ensures that there is no waste existing in a project. Waste refers
to all unproductive processes, tools, employees and so on. Anything that is
unproductive and does not add value to a project should be eliminated, called the
process of elimination of waste.

9. What is the application of zero defects?

Zero defects theory ensures that there is no waste existing in a project. Waste refers
to all unproductive processes, tools, employees and so on. Anything that is
unproductive and does not add value to a project should be eliminated, called the
process of elimination of waste.

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10. What are the objectives of zero defect and zero effect?

To promote adaptation of quality tools/systems and energy efficient manufacturing.

Enable MSMEs for manufacturing of quality products. To encourage MSMEs to
constantly upgrade their quality standards in products and processes. To develop
professionals in the area of ZED manufacturing and certification

PART B

1. Explain Establishing a Quality Culture in an organization.

2. Explain briefly about Facilitators for Optimum Use of Resources and explain
government strengthens the SHG movement.

3. Discuss about to Decreasing lead time in supply chain with advantages.

4. Explain briefly about principles of zero defect.

5. Explain briefly about to apply zero defects in practice with an example.

6. Explain briefly about the Most Critical Elements of Organizational Culture.

7. What are the steps to be followed in lead time reduction.

8. Explain briefly about Human resource and recruitment steps.

9. Explain briefly about Building of Zero defect capabilities

10. Discuss briefly about different organizational culture.

UNIT 5 IMPLEMENTATION AND CHALLENGES

Implementing Checks and Balances in the process, Robust Information Systems,
Dashboard, follow up and robust corrective and preventive mechanism. Concept of
Audits, and continuous improvement from gap analysis, risk assessments etc.

1. What is dashboard in Six Sigma?

A six sigma performance dashboard is a visual tool that helps you monitor and
improve the quality and efficiency of your processes, products, and services. It
displays key performance indicators (KPIs) that measure how well you are achieving
your strategic goals and meeting your customers' expectations.
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2. What is dashboard elements?
A dashboard contains elements, which are the data visualizations, text tiles, and
buttons on the dashboard. This page discusses options for the visualizations within a
LookML dashboard. For settings that affect an entire LookML dashboard, see the
Dashboard LookML reference page.
3. What is dashboard process?
o create a dashboard that provides a comprehensive overview of everything, you
should present critical data that provides an overview of past trends, insights that
offer a forecast of future outcomes, and real-time data that shows what's happening in
real-time.
4. What is dashboard function?
Dashboards are useful for monitoring, measuring, and analyzing relevant data in key
areas. They take raw data from many sources and clearly present it in a way that's
highly tailored to the viewer's needs—whether you're a business leader, line of
business analyst, sales representative, marketer
5. What is robust information system?
An automated system is called robust if it keeps stability and performance indices in
some permissible range in conditions of disturbances influence without using
adaptation methods.
6. What are 2 features of robust software?
Designing robust programs encompasses three areas:
 protection against unexpected user inputs or actions, such as a user entering a letter
where a number was expected.
 confirming that users on a computer system are who they say they are.
 minimising or removing bugs.
7. What do you mean by checks and balances process?
checks and balances. noun plural. : a system that allows each branch of a government
to amend or veto acts of another branch so as to prevent any one branch from having
too much power.
8. What is by the system of checks and balances?
The system of checks and balances is a system of horizontal distribution of power
between the different organs of a government, such as a legislature, executive, and
judiciary. In the Indian context, the legislature, executive, and judiciary share the
powers and keep a system of checks and balances among each other.
9. What is a dashboard and scorecard?
A scorecard is a method of tracking and assessing an organization's progress over

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 time. Dashboards are commonly used as a tool for decision-making by middle and
lower-level management. Leaders in an organization often use scorecards to help
them make important strategic decisions.
10. What is called dashboard?
A dashboard (also called dash, instrument panel or IP, or fascia) is a control panel set
within the central console of a vehicle or small aircraft. Usually located directly
ahead of the driver (or pilot), it displays instrumentation and controls for the vehicle's
operation.

11. What is the concept of audit?

Definition: Audit is the examination or inspection of various books of accounts by an
auditor followed by physical checking of inventory to make sure that all departments
are following documented system of recording transactions. It is done to ascertain the
accuracy of financial statements provided by the organisation.
12. What is the process audit concept?
A process audit is a structured review of an organization's processes to identify where
improvements can be made. Process audits can help organizations improve the
efficiency and effectiveness of their operations by identifying areas where
improvements are needed.
13. What is audit flowchart?
Audit flowcharts provide a way to understand the project management process that
takes ahead the forward solution. The audit flowcharts sample demonstrates the flow
of a project management audit process and increases the company's efficiency.

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14. What is risk assessment in Six Sigma?

Conducting a risk assessment can help evaluate the degree of risks hat any potential
events may have on an organization's ability to achieve its goals. Six Sigma tools like
cause-and-effect matrix, risk matrix, and failure mode and effects analysis can be
used to convert qualitative approaches to quantitative methods.

15. What are the 6 types of risk assessment?

Organizations can take several approaches to assess risks—quantitative, qualitative,

semi-quantitative, asset-based, vulnerability-based, or threat-based. Each
methodology can evaluate an organization's risk posture, but they all require
tradeoffs.

16. What are 3 types of risk assessment?

Different types of risk assessments
 Baseline risk assessments (Baseline HIRA)
 Issue based risk assessments (Issue based HIRA)
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  Continues risk assessments (Continues HIRA)

17. What is a risk methodology?

Risk assessment involves the evaluation of risks taking into consideration the
potential direct and indirect consequences of an incident, known vulnerabilities to
various potential threats or hazards, and general or specific threat/hazard information.

18. What is risk assessment and types?

A risk assessment is a process that organizations use to identify potential hazards
within the workplace and analyze the risk that they pose. Organizations also use risk
assessment processes to identify potential solutions to reduce risks or plans of action
in the event of a hazard or danger.

19. What is gap analysis in Lean Six Sigma?

Gap analysis identifies areas of a business that need to be improved to achieve the
desired future state. Typically, these gaps can be controlled and closed by careful use
of metrics such as KPIs, which are critical to defining future business strategy

20. What are the steps in a gap analysis?

The four steps of a gap analysis are:

1. Identify the current situation. Define what is important for you in your department or
organization. ...
2. Set S.M.A.R.T goals of where you want to end up. S.M.A.R.T. ...
3. Analyze gaps from where you are to where you want to be. ...
4. Establish a plan to close existing gaps.

PART B
1. Discuss briefly about Lean Manufacturing Audit with advantages and disadvantages.
2. What Does a Corrective and Preventive Action (CAPA) Form Include?
3. Explain types of risk assessment
4. Explain the concept of audit with flowchart.

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5. Discuss about dashboard in sixsigma.
6. Explain berifly about Robust Information Systems
7. Discuss about implementing Checks in the process
8. Discuss about implementing Balances in the process
9. Explain about robust corrective and preventive mechanism.
10. Discuss briefly about Lean Audit to help an industry to achieve the goals with
examples.

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