Author: Alphadi Team

The Andon signal (Japanese for “paper lantern”) is a method used to visualize the status of a process. Colored signals are used to indicate problems.

A work instruction is a document that provides a detailed description of a specific task, explaining who, when, where, and with what tools or methods the task should be performed, as well as any settings or parameters required. Work instructions are typically linked to processes, products, or specific workstations.

If needed, they also explain the purpose and guidelines. Since they are workplace-specific, they are readily available where they are needed. Additionally, they are required for QM-documentation. Work instructions differ from procedural instructions: While work instructions are designed to detail individual tasks, procedural instructions offer an overview of all steps or tasks involved in a procedure and present them in a sequential order.

An A3 problem-solving report is a report from quality management in A3 size (DIN A3), which compactly presents problem statements and details about their causes, thereby providing a basis for identifying and implementing corrective actions. There are various types of A3 reports, all structured to fit all necessary information on a single sheet of paper. The most well-known is the A3 problem-solving report. In the upper left quadrant, the problem is described, while the lower left quadrant lists the measures for identifying its causes and proposed solutions. The results of the analysis are recorded in the upper right quadrant, and the activities for implementing the solutions are noted in the lower right quadrant.

5 Why is a questioning technique used in quality management to identify one or more root causes of a problem. The identified root causes should be measurable. 5 Why was developed by Taiichi Ohno (Toyota Production System). It is a simple and effective tool to identify the root causes of a problem. By repeatedly asking “Why” the true causes are uncovered. The number 5 is merely a guideline; sometimes you find the root cause after asking “Why” twice, sometimes after asking ten times.

The „Seven Supplier Questions“ is a tool used to establish a basis for process optimization as well as for identifying problems and areas for improvement, ultimately aiming to achieve a high level of customer satisfaction. The focus is on customer friendliness and service. The processes and the products and services provided are examined and optimized from the customer’s perspective. The questions asked depend on the objectives and the customer. For example, the following questions can be posed: (1) Who is my customer (internal/external)? (2) What does my customer need from me? (3) What expectations does my customer have of me? (4) What am I currently offering them? (5) Where am I falling short of their expectations? (6) What can I do to meet their expectations? (7) What actions will I take?

TPM, short for Total Productive Maintenance, is a concept developed in Japan to prevent equipment failures. It optimizes and standardizes the maintenance concept. TPM is based on the principles of autonomous maintenance, aiming to increase equipment effectiveness, but has now expanded to eight TPM pillars – including continuous improvement, autonomous and planned maintenance, quality preservation, and application in administration – with fundamental components such as PDCA, Kaizen, and 5S serving as the foundation. TPM is a holistic concept and requires the participation and support of all employees for successful implementation.

The concept Y=f(x) reflects the type of correlation between the inputs (x’s) and the output Y, which is the result of the process. The process itself is represented by f. This is a level-thinking approach that runs as a common thread through DMAIC. The formula is used when the output (Y) of a process (f) needs to be changed/improved, and the process inputs or causes (x’s) must be identified to achieve the desired state. In Six Sigma, measurements and analyses are conducted for this purpose. At the same time, the concept helps in identifying underlying root causes – also symbolized by x’s – that negatively impact Y. Y=f(x) thus serves as a foundation for process optimization.

SMED (Single Minute Exchange of Die) is a Lean Management method focused on reducing setup times for machines.

Internal setup can only be performed when the machine is turned off. Activities that can be performed while the machine is running are considered external activities. When converting internal activities to external activities, ensure that all required materials and tools are prepared during the production of the preceding product.

The Validate Phase is the sixth phase in the DMAIC roadmap and follows the Control Phase. It is conducted to confirm that the project and the Control Phase are functioning successfully and that the project is sustainable. Typically, this involves a formal meeting between the project’s sponsor and controller to validate the financial results of the project. Since not all actions from the implementation plan created in the Improve phase are completed by the end of the Control Phase, the Validate Phase is a good way to assess the success of the Control Phase. It usually takes place about six months after the Control Phase. It is also common to conduct the Validate Phase twice, both six months and twelve months after the Control Phase. If the financial results are favorable, the project can be considered successfully completed, and the Green/Black Belt can fully focus on the next project.

The abbreviation SPC from Six Sigma stands for Statistical Process Control. It is a tool used to monitor and assess processes regarding their performance and effectiveness. SPC ensures that processes operate in a controlled manner, meaning they are stable and deliver the intended performance, while also identifying processes that are out of control so that corrective actions can be taken. Statistical process control uses quality control charts—known as control charts—to visualize the progress of a process and the development of critical input and/or output variables.