Our glossary for guidance - Category Tools

The three MU`s are a component of KAIZEN and refer to the three central causes of error

• Muda (waste of resources) (see 7 types of waste)
• Muri (overload related to employees and machines)
• Mura (imbalance or irregular processes)

The 5 Whys is a method for cause-effect analysis. The purpose of this method is to find the real cause of the problem that has occurred - as well as to safeguard the remedial action that has been identified.

Note: The number of whys is not limited to five! It should be continued until the real cause is found. This can already be achieved after asking three times.

The 5A methodology is a modified version of the 5S method and stands for:

• Sorting out (Aussortieren)
• Tidying up or ergonomically arranged work equipment (Aufräumen bzw. ergonomisch angeordnete Arbeitsmittel)
• Workplace cleanliness (Arbeitsplatzsauberkeit)
• Make arrangement a rule (Anordnung zur Regel machen)
•  Adhere to and improve all points (Alle Punkte einhalten und verbessern)

The 5S methodology is a component of KAIZEN and refers to the five principles for workplace design that are the basis for efficient and error-free work processes:

• Seri (tidy up)
• Seiton (Same place for the same object)
• Seiso (Keeping the workplace continuously clean)
• Seiketsu (standardize work processes)
• Shitsuke (Keep order and cleanliness)

The 6Rs are a lean management tool and aimed at optimal customer orientation:

• the right part or product
• in the right quantity
• at the right time
• at the right place
• in the right quality
• at the right price.

Waste in this context refers to the wasting of time or resources and does not create value. In particular there are the following seven types of waste (alternatively: TIMWOOD):

• T – Transport
• I – Inventory
• M – Motion
• W – Waiting
• O – Over-Production
• O – Over-Engineering
• D – Defects

The 8D report is a document that is used in the processing of a complaint. The acronym stands for the eight process steps (disciplines):

• D1 - Assembling the team
• D2 - Describing the problem
• D3 - Determine immediate measures
• D4 - Analyse the cause(s) of the problem
• D5 - Plan corrective action
• D6 - Implement corrective actions
• D7 - Prevent recurrence of error
• D8 - Appreciate the team's performance

The 8D methodology parallels the DMAIC methodology on which Six Sigma is based, with the disciplines D1, D2 and D5 corresponding to the "D" Define process, D3, D5 and D6 to the "I" Improve process, D4 to the "M" Measure or "A" Analyze process and D7 to the "C" Control process.

The affinity diagram, also called affinity board, belongs to the so-called "New Seven Management Tools N7 or M7". It can be used to organize the outcome of a brainstorming session by structuring ideas or different verbal statements.

Cause Effect Diagram

Cause and effect matrix or prioritisation matrix.

CAPA is an acronym for Corrective Actions and Preventive Actions and is used to sustainably correct a defect and prevent its recurrence. The CAPA process is thus the equivalent of the 8D report, which is used in different industries (8D report e.g. automotive and CAPA e.g. medical devices industry).

The Continuous Improvement Process (CIP) is usually equated with the Japanese KAIZEN, since CIP is also about continuous improvement in small steps to make companies competitive. CIP refers to product, process and service quality.

The correlation diagram graphically represents the target value (value that is to be influenced) and the control value (value that can be influenced) and shows pairs of values - which may reveal correlations.

A decision tree visualises decision rules through the hierarchical, sequential representation of decisions. The consequences in each decision are based on the following situations and help to evaluate decisions and show new starting points for further alternative actions. Note the probability of occurrence to make the decision tree manageable.

A design FMEA (D-FMEA), also called a construction FMEA (K-FMEA), examines the influences and potential failure modes during the manufacturing and assembly of a product. The method refers in particular to the systematic errors within the design phase.

Design for Six Sigma.

Stands for the standardised Six Sigma phase model

• Define
• Measure
• Analyse
• Improve
• Control

The fault record card uses attributive tests, i.e. only the number of faulty parts is recorded on the fault record card (no measured values). Thus, only an evaluation of the number of defects can be given.

FMEA stands for Failure Mode and Effects Analysis. Like FMECA (Failure Mode and Effecty Critical Analysis), FMEA is an analytical method (reliability technique) for identifying potential weaknesses, evaluating them and introducing appropriate measures, as well as evaluating them until they are within the tolerance range.

The formal principle is applied in project management to translate imponderables and risks into calculable processes.

A hardware FMEA (HW FMEA for short) examines the risks in the field of hardware and electronics.

The histogram is a graphical evaluation / visualisation of a distribution function (frequency/time).

With the help of the interrelationship diagram, complex interrelationships can be represented more simply, but also integrated in networks. These serve the general planning of projects / interrelationships. With this representation it is quite easy to show the actual core and support processes and their interactions.

The Ishikawa diagram is one of the best-known tools for identifying the cause of an error in a categorised way. In the meantime, Ishikawa uses the 7Ms (man, machine, method, material, measurement, environment, management) and takes into account their contributions to the problem.

KAIZEN consists of the Japanese symbol KAI "change" and the symbol ZEN "good" and stands for change for the better. KAIZEN is a synonym for continuous improvement in small steps and is in principle a permanent interpretation of the PDCA cycle.

KAIZEN uses the Seven Tools Q7 for improvement work.

Lean management is a philosophy based on 6 basic strategies:

• continuous material flow
• simultaneous engineering
• strategic use of capital
• Company as a family
• proactive marketing
• comprehensive quality management

The new seven management tools "M7" (or also called "N7") are composed of the following methods:

• Affinity diagram
• Interrelationship diagram
• Tree diagram
• Matrix diagram
• Portfolio
• Network diagram
• Decision tree

Within a matrix diagram, relationships and interactions of two different groups of characteristics are represented and evaluated.

With the help of a network diagram, logical connections can be shown and thus enable the determination of critical points/processes.

Pareto analysis separates the "important" from the "less important" causes of problems. It thus presents the causes of problems in order of the importance of their effect.

So-called portfolio matrices, on which a large number of so-called tools are based, are structured as follows:

• 2-dimensional
• internal dimension on the abscissa
• external dimension on the ordinate - dividing lines (2; 4,...) to separate matrix segments

A process FMEA (P-FMEA for short), based on the design FMEA, investigates the influences and potential failure opportunities in the production or performance process.

In 2007, the VDA combined the system FMEA and the HW/SW/design FMEA to form the so-called product FMEA, since the system under consideration cannot usually be resolved unambiguously.

The seven quality tools (Q7) are composed as follows:

• Fault record card
• Histogram
• Pareto analysis
• Stratification
• Ishikawa diagram
• Correlation diagram
• Quality control chart

Statistical process optimisation or method for quality management that describes the freedom from errors of processes with 99.99966% certainty and thus reduces the audit effort through robust processes.

A software FMEA (SW-FMEA for short) examines the risks related to the programme code to be generated.

A system FMEA (S-FMEA) examines the influences and potential failure opportunities in the interaction of subsystems in a system network. However, special attention is paid to the interfaces of the individual components and the effects of their interaction.

The tree diagram belongs to the so-called "New Seven Management Tools N7 or M7"

With the help of this method, connections and processes with an increased degree of complexity can be displayed in a structured manner. Through this structured and logical visualization, risks can be detected early and measures can be initiated.

Turtle analysis is used for the holistic and transparent analysis of a process with all its aspects and is used to identify weaknesses in a process, especially in interactions and interfaces with other processes.