Lean Six Sigma Green Belt & Black Belt Oefenboek

1. WORLD CLASS PERFORMANCE 13
1.1 COMPETITIVE STRATEGIES 13
1.1.1 Lean and Six Sigma applications – Six Sigma organisatie 13
1.2 HISTORY OF CONTINUOUS IMPROVEMENT 13
1.3 PHILOSOPHY & PRINCIPLES 13
1.3.1 Lean principles – De 14 principes van Toyota (TPS) 13
1.3.2 Lean principles – Lean denken 14
1.4 ORGANIZATIONAL PROCESS MANAGEMENT 16
1.4.1 Business performance measures – EFQM / INK-model en dimensies 16
1.4.2 Business performance measures – EFQM / INK-spinnenweb 16
1.4.3 Business performance measures – Financiële kengetallen (Lean Accounting) 17
1.4.4 Business performance measures – Tegenwerkende accountingregels (Lean Accounting) 17
1.5 PROJECT SELECTION PROCESS 18

2. PROCESS IMPROVEMENT DEPLOYMENT 19
2.1 MANAGEMENT OF CHANGE 19
2.2 LEADERSHIP 19
2.2.1 Effective communication – Effectief vergaderen 19
2.2.2 Team performance, evaluation and reward – Motiveren en betrekken 19
2.3 TEAM DEVELOPMENT 19
2.3.1 Training Deployment – Kernpunten 19

3. PROJECT MANAGEMENT 20
3.1 TEAM FORMATION 20
3.2 PROCESS IMPROVEMENT ROADMAPS 20
3.3 VOICE OF CUSTOMER (VOC) 20
3.3.1 Customer Identification – Innovatiesubsidies 20
3.4 PROJECT CHARTER 21
3.5 PROJECT MANAGEMENT TECHNIQUES 21
3.5.1 Time management – Efficiënte bijeenkomsten 21
3.5.2 Time management – Projectvertraging 21
3.5.3 Project risk analysis and mitigation – Familiebedrijf 21
3.5.4 Lessons learned – One Point Lesson 22

4. CIMM LEVEL I – CREATING A SOLID FOUNDATION 23
4.1 ORGANIZED WORK ENVIRONMENT (5S) 23
4.1.1 Organised work environment (5S) – 5S activiteiten 23
4.2 STANDARDIZED WORK 23
4.2.1 Standardized work and Documentation – Standard Operating Procedures (SOP) 23
4.2.2 Standardized work and Documentation – Effectieve procesbeheersmethoden 23
4.3 QUALITY CONTROL & QUALITY ASSURANCE 24
4.3.1 Ongoing evaluation and auditing – Japanse cultuur 24

5. CIMM LEVEL II – CREATING A CONTINUOUS IMPROVEMENT CULTURE 25
5.1 KAIZEN 25
5.1.1 Kaizen events – Verspaningsafdeling 25
5.2 BASIC QUALITY TOOLS 28
5.2.1 Visualization of data – Kolommen stapelen 28
5.2.2 Visualization of data – Kolommen transponeren 28
5.2.3 Visualization of data – Subset data via een formule 28
5.2.4 Visualization of data – Samenvoegen tekst uit 2 kolommen 29
5.2.5 Basic Quality tools – Paretodiagram 29
5.2.6 Basic Quality tools – Staafdiagram 29
5.2.7 Basic Quality tools – Taartdiagram 29
5.2.8 Basic Quality tools – Boxplot 30
5.2.9 Basic Quality tools – Histogram 30
5.2.10 Basic Quality tools – Interval plot (met groepen) 30
5.2.11 Basic Quality tools – Interval plot 30
5.2.12 Basic Quality tools – Probability distribution plot 30
5.2.13 Basic Quality tools – Line plot 31
5.2.14 Basic Quality tools – Time series plot 31
5.2.15 Basic Quality tools – Probability plot 31
5.2.16 Basic Quality tools – Marginal plot 31
5.3 BASIC MANAGEMENT TOOLS 31

6. CIMM LEVEL III – CREATING STABLE AND EFFICIENT PROCESSES 32
DEFINE 32
6.1 PROCESS MAPPING 32
6.1.1 High level process description – Pannenkoek (SIPOC) 32
6.1.2 High level process description – Pannenkoek (Process mapping ) 32
6.1.3 High level process description – Pannenkoek (Cause & Effect matrix) 33
MEASURE 33
6.2 LEAN PERFORMANCE METRICS 33
6.2.1 Total Productive Maintenance (TPM) – Overall Equipment Effectiveness (OEE) 33
6.2.2 Total Productive Maintenance (TPM) – Afvullijn OEE 34
6.2.3 Types of data – Schaaltypen 34
ANALYZE 35
6.3 VALUE STREAM MAPPING (CURRENT STATE) 35
6.3.1 Value Stream Mapping (Current State) – Zaklantaarn productie - ENNA 35
IMPROVE 40
6.4 REDUCING MUDA (WASTE) 40
6.4.1 Waste identification – Logistiek proces inkomende goederen 40
6.5 REDUCING MURI (OVERBURDEN) 41
6.5.1 Flow – Cellen 41
6.5.2 Flow – Penny Fab 43
6.6 REDUCING MURA (UNEVENNESS) 45
6.6.1 Pull – Kanban, voorraadverloop (Shop Floor Control) 45
6.6.2 Pull – Oppervlaktebehandeling 46
6.6.3 Quick Change Over (SMED) – Omstellingen in dienstverlenende - administratieve processen 47
6.6.4 Quick Change Over (SMED) – SMED tooling 47
6.7 VALUE STREAM MAPPING – FUTURE STATE 48
6.7.1 Value Stream Mapping (Future State) – Zaklantaarn productie - ENNA 48
6.7.2 Value Stream Mapping (Future State) – Spuitgietproces – ENNA 49
6.7.3 Value Stream Mapping (Future State) – Assemblageproces – ENNA 49
CONTROL 50
6.8 FIRST TIME RIGHT 50
6.8.1 Failure Mode and Effects Analysis (pFMEA) – Pannenkoek (pFMEA) 50
6.8.2 Jidoka & Poka Yoke – Poka Yoke 50

7. CIMM LEVEL IV – CREATING CAPABLE PROCESSES 51
DEFINE 51
7.1 CRITICAL TO QUALITY (CTQ) 51
7.1.1 CTx Flowdown – Pannenkoek 51
7.1.2 CTx Flowdown – Hotel 52
MEASURE 52
7.2 SIX SIGMA PERFORMANCE METRICS 52
7.3 STATISTICS 52
7.3.1 Basic terms – Gemiddelde en mediaan 52
7.3.2 Basic terms – Variantie, standaarddeviatie en range 52
7.3.3 Basic terms – Variantie en standaarddeviatie 53
7.3.4 Descriptive statistics – “Histogram with fit and groups” van een nokkenas 53
7.3.5 Descriptive statistics – Populatie versus steekproef 53
7.3.6 Descriptive statistics – Steekproefmethodes 53
7.3.7 Descriptive statistics – Werpen met 2 dobbelstenen (Som van kansen) 54
7.3.8 Descriptive statistics – Bjorn en Svein (Hoogste kans met dobbelstenen) 54
7.3.9 Descriptive statistics – Dagproductie (Kans met steekproef) 54
7.4 DISTRIBUTIONS 54
7.4.1 Common continuous distributions – Briketten (Normale kansverdeling) 54
7.4.2 Common continuous distributions – Diameter van asjes 55
7.4.3 Common continuous distributions – Steekproef kogellagers 55
7.4.4 Common continuous distributions – Espresso 55
7.4.5 Common discrete distributions – Schroeven 1 (Binomiale kans) 55
7.4.6 Common discrete distributions – Schroeven 2 (Binomiale kansverdeling) 56
7.4.7 Common discrete distributions – Offertes - I 56
7.4.8 Common discrete distributions – Offertes - II 56
7.4.9 Common discrete distributions – Helpdesk (Poisson kansverdeling) 56
7.4.10 Common discrete distributions – Referendum stemgerechtigden 56
7.4.11 Central limit theorem – Proef op de som 57
7.5 MEASUREMENT SYSTEMS 57
7.5.1 Measurement Systems Analysis (MSA) – Positive, Negative, Non-linear and Bias 57
7.5.2 Measurement Systems Analysis (MSA) – Laboratoriummeting (MSA) 57
7.5.3 Measurement Systems Analysis (MSA) – Foliediktemeting (MSA) 58
7.5.4 Measurement Systems Analysis (MSA) – Asje, 50 keer gemeten (Type 1 Gage Study) 59
7.5.5 Measurement Systems Analysis (MSA) – Afwegen chemicalie (Gage Linearity) 59
7.5.6 Attribute Agreement Analysis – Bloedeieren (Attributive Agreement) 60
7.5.7 Attribute Agreement Analysis – Dropfabrikage (Attribute Gage Study) 60
ANALYZE 61
7.6 HYPOTHESIS TESTING 61
7.6.1 Tests for means, variances and proportions – Instellen vulmachine 61
7.6.2 Tests for means, variances and proportions – Asjes draaien 61
7.6.3 Tests for means, variances and proportions – Doorlooptijd subsidieaanvraag 62
7.6.4 Tests for means, variances and proportions – Fastfoodketen 62
7.6.5 Tests for means, variances and proportions – Sportieve studenten 63
7.6.6 Tests for means, variances and proportions – Zuivere munt tossen 63
7.6.7 Paired-comparison tests – Breeksterkte van kabels 63
7.6.8 Paired-comparison tests – Doorbuigen plastic buizen 63
7.6.9 Paired-comparison tests – Distributiecentrum 64
7.6.10 Paired-comparison tests – Callcenter aanbod 64
7.6.11 Goodness-of-fit (Chi square) tests – Jongens en meisjes (Goodness of Fit) 64
7.6.12 Goodness-of-fit (Chi square) tests – Kogeldiameters (Contingentie (kans) Tabellen) 65
7.6.13 Goodness-of-fit (Chi square) tests – Ongelukken en leeftijd 65
7.6.14 Non-parametric tests – Nieuw logo 65
7.6.15 Non-parametric tests – Titaniumgehalte 65
7.6.16 Non-parametric tests – Rechtsaf slaan 66
7.6.17 Non-parametric tests – Inkomen per stadsdeel 66
7.7 EXPLORATORY DATA ANALYSIS 67
7.7.1 Regression analysis – Plantgroei 67
7.7.2 Regression analysis – Visserslatijn 67
7.7.3 Regression analysis – Marketing Campagne I 67
7.7.4 Regression analysis – Marketing Campagne II 68
7.7.5 Regression analysis – Transportkosten 68
7.7.6 Analysis of variance (ANOVA) – Bloedstollend onderzoek 69
7.7.7 Analysis of variance (ANOVA) – Typesnelheid 69
7.7.8 Multivariate studies – Sinteren van metaal (Multi-Vari chart) 70
7.7.9 Attribute data analysis – Challenger Case 70
7.8 PROCESS CAPABILITY AND PERFORMANCE 71
7.8.1 Process capability studies – Diameter van asjes (Process Capability) 71
7.8.2 Process capability studies – Vulgewicht van tubes 71
7.8.3 Process capability studies – Oven temperaturen 72
7.8.4 Process capability studies – Temperatuur op kantoor 72
IMPROVE 73
7.9 DESIGN OF EXPERIMENTS (DOE) 73
7.9.1 Two-level fractional factorial experiments – Fietsexperiment (DOE fractional factorial) 73
7.9.2 Two-level fractional factorial experiments – Lithografie – 5 factoren 73
CONTROL 75
7.10 STATISTICAL PROCESS CONTROL (SPC) 75
7.10.1 Selection and application of control charts – Xbar & R chart van een nokkenas 75
7.10.2 Selection and application of control charts – Leverancier 75
7.10.3 Selection and application of control charts – Afwijking van nominal (DNOM – Chart) 75
7.10.4 Selection and application of control charts – Regelkaart van LCD-schermen 76
7.10.5 Selection and application of control charts – Regelkaart valse “Out-Of-Control”-meldingen 76

8. CIMM LEVEL V – CREATING WORLD CLASS PRODUCTS 77
8.1 PRODUCT LIFECYCLE MANAGEMENT (PLM) 77
8.2 DEVELOPMENT FRAMEWORKS 77
8.3 DESIGN FOR SIX SIGMA TECHNIQUES 77
8.3.1 Tolerance Analysis – Bol en balk 77

UITWERKINGEN 79
1. WORLD CLASS PERFORMANCE 80
1.1 COMPETITIVE STRATEGIES 80
1.1.1 Lean and Six Sigma applications – Six Sigma organisatie 80
1.2 HISTORY OF CONTINUOUS IMPROVEMENT 80
1.3 PHILOSOPHY & PRINCIPLES 80
1.3.1 Lean principles – De 14 principes van Toyota (TPS) 80
1.3.2 Lean principles – Lean denken 82
1.4 ORGANIZATIONAL PROCESS MANAGEMENT 82
1.4.1 Business performance measures – EFQM / INK-model en dimensies 82
1.4.2 Business performance measures – EFQM / INK-spinnenweb 83
1.4.3 Business performance measures – Financiële kengetallen (Lean Accounting) 84
1.4.4 Business performance measures – Tegenwerkende accountingregels (Lean Accounting) 85
1.5 PROJECT SELECTION PROCESS 86

2. PROCESS IMPROVEMENT DEPLOYMENT 87
2.1 MANAGEMENT OF CHANGE 87
2.2 LEADERSHIP 87
2.2.1 Effective communication – Effectief vergaderen 87
2.2.2 Team performance, evaluation and reward – Motiveren en betrekken 87
2.3 TEAM DEVELOPMENT 88
2.3.1 Training Deployment – Kernpunten 88

3. PROJECT MANAGEMENT 89
3.1 TEAM FORMATION 89
3.2 PROCESS IMPROVEMENT ROADMAPS 89
3.3 VOICE OF CUSTOMER (VOC) 89
3.3.1 Customer Identification – Innovatiesubsidies 89
3.4 PROJECT CHARTER 90
3.5 PROJECT MANAGEMENT TECHNIQUES 90
3.5.1 Time management – Efficiente bijeenkomsten 90
3.5.2 Time management – Projectvertraging 90
3.5.3 Project risk analysis and mitigation – Familiebedrijf 90
3.5.4 Lessons learned – One Point Lesson 92

4. CIMM LEVEL I – CREATING A SOLID FOUNDATION 93
4.1 ORGANIZED WORK ENVIRONMENT (5S) 93
4.1.1 Organised work environment (5S) – 5S-activiteiten 93
4.2 STANDARDIZED WORK 93
4.2.1 Standardised work and documentation – Standard Operating Procedures (SOP) 93
4.2.2 Standardised work and documentation – Effectieve procesbeheersmethoden 93
4.3 QUALITY CONTROL & QUALITY ASSURANCE 94
4.3.1 Ongoing evaluation and auditing – Japanse cultuur 94

5. CIMM LEVEL II – CREATING A CONTINUOUS IMPROVEMENT CULTURE 95
5.1 KAIZEN 95
5.1.1 Kaizen events – Verspaningsafdeling 95
5.2 BASIC QUALITY TOOLS 97
5.2.1 Visualization of data – Kolommen stapelen 97
5.2.2 Visualization of data – Kolommen transponeren 98
5.2.3 Visualization of data – Subset data via een formule 99
5.2.4 Visualization of data – Samenvoegen tekst uit 2 kolommen 100
5.2.5 Basic Quality tools – Paretodiagram 101
5.2.6 Basic Quality tools – Staafdiagram 102
5.2.7 Basic Quality tools – Taartdiagram 104
5.2.8 Basic Quality tools – Boxplot 106
5.2.9 Basic Quality tools – Histogram 107
5.2.10 Basic Quality tools – Interval plot (met groepen) 109
5.2.11 Basic Quality tools – Interval plot 111
5.2.12 Basic Quality tools – Probability distribution plot 112
5.2.13 Basic Quality tools – Line plot 114
5.2.14 Basic Quality tools – Time series plot 115
5.2.15 Basic Quality tools – Probability plot 116
5.2.16 Basic Quality tools – Marginal plot 119
5.3 BASIC MANAGEMENT TOOLS 119

6. CIMM LEVEL III – CREATING STABLE AND EFFICIENT PROCESSES 120
DEFINE 120
6.1 PROCESS MAPPING 120
6.1.1 High level process description – Pannenkoek (SIPOC) 120
6.1.2 High level process description – Pannenkoek (Process mapping) 121
6.1.3 High level process description – Pannenkoek (Cause & Effect matrix) 122
MEASURE 123
6.2 LEAN PERFORMANCE METRICS 123
6.2.1 Total Productive Maintenance (TPM) – Overall Equipment Effectiveness (OEE) 123
6.2.2 Total Productive Maintenance (TPM) – Afvullijn OEE 124
6.2.3 Types of data – Schaaltypen 128
ANALYZE 128
6.3 VALUE STREAM MAPPING (CURRENT STATE) 128
6.3.1 Value Stream Mapping (Current State) – Zaklantaarn productie - ENNA 128
IMPROVE 130
6.4 REDUCING MUDA (WASTE) 130
6.4.1 Waste identification – Logistiek proces inkomende goederen 130
6.5 REDUCING MURI (OVERBURDEN) 131
6.5.1 Flow – Cellen 131
6.5.2 Flow – Penny Fab 131
6.6 REDUCING MURA (UNEVENNESS) 132
6.6.1 Pull – Kanban, voorraadverloop (Shop Floor Control) 132
6.6.2 Pull – Oppervlaktebehandeling 133
6.6.3 Quick Change Over (SMED) – Omstellingen in dienstverlenende - administratieve processen 134
6.6.4 Quick Change Over (SMED) – SMED tooling 135
6.7 VALUE STREAM MAPPING – FUTURE STATE 137
6.7.1 Value Stream Mapping (Future State) – Zaklantaarn productie - ENNA 137
6.7.2 Value Stream Mapping (Future State) – Spuitgietproces – ENNA 138
6.7.3 Value Stream Mapping (Future State) – Assemblageproces – ENNA 140
CONTROL 145
6.8 FIRST TIME RIGHT 145
6.8.1 Failure Mode and Effects Analysis (pFMEA) – Pannenkoek (pFMEA) 145
6.8.2 Jidoka & Poka Yoke – Poka Yoke 146

7. CIMM LEVEL IV – CREATING CAPABLE PROCESSES 148
DEFINE 148
7.1 CRITICAL TO QUALITY (CTQ) 148
7.1.1 CTx Flowdown – Pannenkoek (CTQ Flowdown) 148
7.1.2 CTx Flowdown – Hotel 150
MEASURE 151
7.2 SIX SIGMA PERFORMANCE METRICS 151
7.3 STATISTICS 151
7.3.1 Basic terms – Gemiddelde en mediaan 151
7.3.2 Basic terms – Variantie, standaarddeviatie en range 152
7.3.3 Basic terms – Variantie en standaarddeviatie 152
7.3.4 Descriptive statistics – “Histogram with fit and groups” van een nokkenas 152
7.3.5 Descriptive statistics – Populatie versus steekproef 153
7.3.6 Descriptive statistics – Steekproefmethodes 153
7.3.7 Descriptive statistics – Werpen met 2 dobbelstenen (Som van kansen) 154
7.3.8 Descriptive statistics – Bjorn en Svein (Hoogste kans met dobbelstenen) 154
7.3.9 Descriptive statistics – Dagproductie (Kans met steekproef) 155
7.4 DISTRIBUTIONS 156
7.4.1 Common continuous distributions – Briketten (Normale kansverdeling) 156
7.4.2 Common continuous distributions – Diameter van asjes 159
7.4.3 Common continuous distributions – Steekproef kogellagers 162
7.4.4 Common continuous distributions – Espresso 164
7.4.5 Common discrete distributions – Schroeven 1 (Binomiale kans) 167
7.4.6 Common discrete distributions – Schroeven 2 (Binomiale kansverdeling) 174
7.4.7 Common discrete distributions – Offertes - I 174
7.4.8 Common discrete distributions - Offerte - II 180
7.4.9 Common discrete distributions – Helpdesk (Poisson kansverdeling) 180
7.4.10 Common discrete distributions – Referendum stemgerechtigden 188
7.4.11 Central limit theorem – Proef op de som 189
7.5 MEASUREMENT SYSTEMS 191
7.5.1 Measurement Systems Analysis (MSA) – Positive, Negative, Non-linear and Bias 191
7.5.2 Measurement Systems Analysis (MSA) – Laboratoriummeting (MSA) 197
7.5.3 Measurement Systems Analysis (MSA) – Foliediktemeting (MSA) 199
7.5.4 Measurement Systems Analysis (MSA) – Asje, 50 keer gemeten (Type 1 Gage Study) 202
7.5.5 Measurement Systems Analysis (MSA) – Afwegen chemicalie (Gage Linearity) 206
7.5.6 Measurement Systems Analysis – Bloedeieren (Attributive Agreement) 208
7.5.7 Attribute Agreement Analysis – Dropfabrikage (Attribute Gage Study) 212
ANALYZE 213
7.6 HYPOTHESIS TESTING 213
7.6.1 Tests for means, variances and proportions – Instellen vulmachine 213
7.6.2 Tests for means, variances and proportions – Asjes draaien 215
7.6.3 Tests for means, variances and proportions – Doorlooptijd subsidieaanvraag 217
7.6.4 Tests for means, variances and proportions – Fastfoodketen 219
7.6.5 Tests for means, variances and proportions – Sportieve studenten 221
7.6.6 Tests for means, variances and proportions – Zuivere munt tossen 223
7.6.7 Paired-comparison tests – Breeksterkte van kabels 225
7.6.8 Paired-comparison tests – Doorbuigen plastic buizen 226
7.6.9 Paired-comparison tests – Distributiecentrum 232
7.6.10 Paired-comparison tests – Callcenter aanbod 237
7.6.11 Goodness-of-fit (Chi square) tests – Jongens en meisjes (Goodness of Fit) 239
7.6.12 Goodness-of-fit (Chi square) tests – Kogeldiameters (Contingentie (kans) Tabellen) 240
7.6.13 Goodness-of-fit (Chi square) tests – Ongelukken en leeftijd 242
7.6.14 Non-parametric tests – Nieuw logo 243
7.6.15 Non-parametric tests – Titaniumgehalte 245
7.6.16 Non-parametric tests – Rechtsaf slaan 247
7.6.17 Non-parametric tests – Inkomen per stadsdeel 248
7.7 EXPLORATORY DATA ANALYSIS 251
7.7.1 Regression analysis – Plantgroei 251
7.7.2 Regression analysis – Visserslatijn 254
7.7.3 Regression analysis – Marketing Campagne I 259
7.7.4 Regression analysis – Marketing Campagne II 261
7.7.5 Regression analysis – Transportkosten 264
7.7.6 Analysis of variance (ANOVA) – Bloedstollend onderzoek 272
7.7.7 Analysis of variance (ANOVA) – Typesnelheid 275
7.7.8 Multivariate studies – Sinteren van metaal (Multi-Vari chart) 279
7.7.1 Attribute data analysis - Challenger Case 280
7.8 PROCESS CAPABILITY AND PERFORMANCE 284
7.8.1 Process capability studies – Diameter van asjes (Process Capability) 284
7.8.2 Process capability studies – Vulgewicht van tubes 286
7.8.3 Process capability studies – Oven temperaturen 288
7.8.4 Process capability studies – Temperatuur op kantoor 291
IMPROVE 294
7.9 DESIGN OF EXPERIMENTS (DOE) 294
7.9.1 Two-level fractional factorial experiments – Fietsexperiment (DOE fractional factorial) 294
7.9.2 Two-level fractional factorial experiments – Lithografie – 5 factoren 299
CONTROL 302
7.10 STATISTICAL PROCESS CONTROL (SPC) 302
7.10.1 Selection and application of controlcharts – Xbar & R chart van een nokkenas 302
7.10.2 Selection and application of control charts – Leverancier 303
7.10.3 Selection and application of control charts – Afwijking van nominaal (DNOM –Chart) 304
7.10.4 Selection and application of control charts – Regelkaart van LCD-schermen 305
7.10.5 Selection and application of controlcharts – Regelkaart valse Out-Of-Control meldingen 306

8. CIMM LEVEL V – CREATING WORLD CLASS PRODUCTS 309
8.1 PRODUCT LIFECYCLE MANAGEMENT (PLM) 309
8.2 DEVELOPMENT FRAMEWORKS 309
8.3 DESIGN FOR SIX SIGMA TECHNIQUES 309
8.3.1 Tolerance analysis – Bol en balk 309

OVERZICHT VAN OEFENINGEN VOOR INDUSTRIE EN DIENSTVERLENING OP GB EN BB NIVEAU 315