Measure Phase

45 important questions on Measure Phase

What are Key Performance Indicators?

KPI's are measurements that reflect the process.
Also reflect the VOC
Is based on CTQ

What is a KPI Tree?

Is a visual method of displaying a range of process measures that are relevant to your project or process. Handy for displaying different measurement categories
It contains a balance of measures of both effectiveness and efficiency/

What is Queue Time?

The Queueing time between two steps
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What is Work in Process?

The number of products or services waiting between to process steps, or being processed within a step.

What is Total Lead time?

The total time it takes for a product/service to pass through the whole process from start to finish.

What is Completion Rate?

The number of ''things'' that are completed within a time frame

What is Process Cycle Efficiency?

This is the primary Lean measure combining both time and value.
It is calculated by: Total value add Time / Total Lead Time

How do the PCE percentages work?

Typical service processes have up to 10%, world class is around 50%
Typical production processes have up to 20%,  world class is around 25%

A large advantage of PCE is that is can be used consistently.

How is average Lead time Calculated?

WIP / completion Rate

What is Takt time?

It is an important Lean measure and represents the drum beat of a process.

How is Takt Time calculated?

Available work time / Customer demand

OEE is linked to the which Lean components?

Total productive maintenance
Rapid changeovers
Reducing waste

How do you get the Performance % in OEE?

Actual output / Predicted output

How do you get the Quality % in OEE

Good parts produced / Total parts produced

What are two key features to a Histogram?

The central position and its Spread

How can the statistic average be described as?

Mean, Xbar, Mu (u symbol)

Spread means how much variation lies within the process, what statistics can be used to measure variation?

Range
Standard deviation

When is the normal distribution applied when measuring continuous data?

Not all the time, the validity of the normal model needs to be checked

When is the Poisson distribution used when measuring count data?

Always, if the process is in control

When is the Binomial model used when measuring Attribute data?

Always applied, if the process is in control

What are the common statistics for Count data?

Defect per Unit (DPU)

What is the common statistic for Attribute data?

Percentages (proportion)

What are useful graphs for Attribute data?

Time series plot
100% stacked bar chart
Pareto chart

What are the steps to take when doing Measurement System Analysis?

Is the resolution acceptable? yes/no
Is the level of bias(accuracy) acceptable? yes/no
Is the level of precision acceptable? yes/no

What is Bias (errors)?

Consistent errors that do not increase variation, but do shift the data in way that it is displayed inaccurately.

In precision errors there is repeatability and reproducibility, what is the definition of both exactly?

Repeatability: Differences caused by the gauge itself, they refer if the gauge is capable of repeating the same measurements with all other factors constant.
Reproducibility: Differences in the way people do the measurement, is one person capable of repeating the measurement action of the person before him.

How are precision errors addressed?

By Gauge R&R studies
Attribute Agreement Analysis
MSA drilldowns

What is the first step in MSA?

Checking the resolution to ensure that variation is effectively visible.

GR&R stands for Gauge Repeatability and Reproducibility, but what is it exactly?

Measures precision errors by taking one part and measuring it several times, with multiple people.

There are 2 GR&R acceptability criteria, what are they?

Percentage of total variation
Percentage of total tolerance

What are the levels of acceptance in GR&R?

Unacceptable >30%
Marginal <30%
Good <20%
Excellent <10%

What is an MSA drilldown for?

This is a great method of checking if your data represents what it is supposed to.

What is MSA Drilldown?

It is a structured approach to check to the quality of your data. The underlying principle is that you should not use data if you do not know where it came from.

Data is skewed right, what does this mean?

Positive Skew
The distribution has most data on the left, usually found when measuring time.


Data is skewed left, what does this mean?

Negative Skew
Distribution of data is to the right, usually happens when there is a top limit. (deadline/Spec limit)

What is process capability?

Range of KPIs that measure the ability of the process to deliver customer requirements.

What is the first step the process capability roadmap?

To calculate the % of defective product/service

What kind of systems are used for continuous data relating to capability?

CP
CPK
Normal Data
Non normal data

What kind of systems are used for count data relating to capability?

% defective
=(1-FTY)
=(1-e-dpu )

What kind of systems are used for attribute data relating to capability?

Good and Bad.
Defects are already given, but it is important to ensure good/bad is customer driven

What is the third step for the capability roadmap?

Convert into a sigma level

What is the fourth step is the Capability roadmap?

Calculate sigma shift, if there is no alternative use 1.5 Sigma shift.

How is CP calculated?

(USL - LSL) / 6 x Sigma
Sigma is the standard deviation in this case
Also, CP is to calculate the potential capability

How is CPk calculated?

(Nearest spec - average) / 3 x Sigma
Sigma is standard deviation
CPk reflects actual process capability

What is Sigma level?

Sigma level is the same as the Z value in the Z table.
Works as a percentage on a normal distribution
Can be measured as on the left/below of the USL/

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