Quality=Performance/Expectation Lean Enterprise: Emphasize the prevention of waste Types of waste: Non-value added and unnecessary, Non-value added

and necessary, unevenness or variation in quality cost or delivery (such as under production). Overstressing people equipment or systems. Categories of waste: Overproduction, Waiting, Transportation, Defects, Inventory, Motion, Extra Processing. Workplace Organization (5Ss): Sort(Categorize), Straighten(Eliminate wasted motion), Shine(good housekeeping), Standardize(Document/Procedure), Sustain(Maintain: Charts, audits, etc) & Safety. Concept Flow: Product should flow continuous, use one piece flow (instead of batch). One piece flow reduces process, time, prevents waits, reduces labor due to storage of batchs, reveals defects quicker, reduces handling damage, provides flexibility, helps reveal non-value action. Equipment needs quick change overs. Cell technology; different machines close together for flexible human resources. Inventory Control: Just in Time inventory control. Pull signal (kaban) used to trigger that replacement is needed. Kaban contains product description and quantity. Takat (beat) pace for production. Kaizen- The continuous strive for small improvements that make process, efficient, effective, in control adaptable. Preferably cheap and easy. Relies on culture and operator input. Kiazen Blitz is a 3-5 day workshop utilized to immediate action to improve a process. Value Stream-specific activities required to design, order, produce and deliver. Flow of materials from raw to product. Perfect value stream; meets quality, no downtime, eliminates waste of materials, meet demand. Value Stream Map: Best to map current and ideal processes. Six Sigma; statistical concept measures nonconformities. Rejects at 0.002 parts/million DMAIC- Define, Measure, Analyze, Improve, Control. To improve cycle time, quality and cost. Pareto Diagram: Ranks classifications ranks data in descending order left to right (other on far right). For problems, causes, nonconformities. May have cumulative line. Left axis is units, right axis is percent. Used to identify important problems. 80/20- 80% of results from 20% of items. Cause and Effect Diagrams: #1 (Cause and enumeration) Used to evaluate bad or good effects. For every effect likely numerous causes. Broke down into major and minor causes. Define problem then brainstorm effects. Used to: Analyzing actual conditions for quality improvement. Elimination of conditions cause non-conformances. Standardization of operations, education/training. #2Dispesion analysis- Each major branch filled first, object to analyze the cause of variability. #3 Process analysis(looks different)-write each step of process, minor are then connected to major. Easier to construct because it follows a sequence. Process flow diagram: process map shows flow of product as it flows through stations. Much like a make your own adventure map. Check sheets: to ensure data are collected carefully for process control and problem solving. Data should be presented such can be easily analyzed. Scatter Diagram: graphical relation between to variables, x & y. Shows cause and effect. Can have: Posotive Correlation, Negative, No, Curvilinear, May exist. Coefficient of Correlation: Formula that results in a number between -1 and 1, The closer to 1.0 the better. Histogram: shows process capability and desired. Such as upper and lower hole tolerance with actual values plotted in bar graph form. (remember normal distribution) Control charts: horizontal scatter with UCL and LCL. Based off of time. Can be used to identify and correct out of control conditions, or testing/evaluating ideas. As pattern reaches perfection it will come closer to center line. Run Chart is like control chart but without limits to show process over time. Statistics: The science that deals with collection, tabulation, analysis, interpretation, presentation of data. Inductive Statistics; conclusion based on limited data that may not be representative of population. Variable: those quality characteristics that are measurable. Continuous means capable of subdivision (i.e. decimal points). Discrete- cannot be sub divided (i.e. whole numbers)

Attribute: quality characteristics that are classified as conforming/non-conforming. Precision=one unit of lowest shown value (6.2=precision of 0.1) r.e. relative error = number divided by g.p.e., g.p.e. = how far off rounding could be. Significant figures; when multiplying, dividing, exponent result has same quantity of numbers and the smallest number of numbers input. When adding and subtracting, result has lowest decimal as least precise input. Data-Frequency distribution; how data occurs in each sub division. Array- place data in decending or ascending order. Histogram-Frequency distribution in bar graph form. Cumulative (adding each frequency together as graph proceeds) frequency results in an increase of data from left to right. Cell-grouping within a specific boundary of values along the abscissa (horizontal axis). Range= Xh - Xl , recommended to have no more than ten observations in a range. Cell Interval= Distance between adjacent (recommend odd numbers so they stay the same) cell midpoints I = R/(1 + 3.322logn). h = # of cells = R/i Cell boundaries are upper and lower limits of each cell. Histogram-Used to: Solve problems, Determine capability, compare to specs, suggest shape of pop, indicate discrepancies such as gaps. Skew left, skew right, bimodal (two peaks), normal (symmetrical), Leptokurtic (high), Platykurtic (flat). Polygon-Dots placed at each midpoint on top of histogram bars, bars removed, lines drawn in-between dots. Measure of central tendency-Average of grouped data(multiply each data by frequency), average of ungrouped data (unorganized), weighted average(average of frequencies (cell rage determines data grouping)). Skewness- Number which describes datas depart from symmetry. Normal distributions have 0 skewness. Kurtisus- peakedness of the data. Normal peakness is 3.0. Coefficient of Variation- measure of how much variation exists around the mean CV = (%100)/ Sample - is a group of units selected from a larger group (the population)( Average) Population whole collection of measurements of all pieces. ( Mean) Normal Curve = symmetrical, unimodal, bell shaped with mean=median=mode. Z= Standardized normal value = Z = (Xi - )/ Probablity Plots- Used to test normality of data on probability paper, judged by visual of best fit line. Chi Square Goodness Fit- Formula used by excel to test normality, requires a population of 125. Varitations- In the piece, piece to piece & time to time. Sources: equipment, material, environment, operator. Chance cause- random variation. Assignable cause- identifiable variation. Control Charts-Xbar and R charts. Xbar chart shows plots on graph based on averages of subcategories. R chart shows plots on graph based on range of subcategories. Horizontal scatter with UCL & LCL. Used for: quality improvement, process capability, decisions for specifications, decisions production process, for discussion of produced items. Control Chart- #1 Select the quality characteristic, #2 choose subgroup, #3 collect data, #4 determine trial center line and control limits, #5 establish the revised center line and limits, #6 achieve objective. UCL=Upper Control Limit=3, USL= Upper Specification Limit. Out of control process-change in process due to assignable cause. Change or jump in level, trend or steady change in level, recurring cycles, two populations, mistakes in measuring or inspection. Out of control point- usually when it falls outside of 3. But could also be from a point inside 3 that does not follow normal pattern. GR&R-Guage repeatability and reproducibility. Observed value = True Value + Measurement Error. If precision/total variation = 0.1 or less then it is acceptable. Greater than 0.3 is not acceptable.