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Six Sigma

Subjects : certifications, six-sigma, business-skills

Instructions:

Answer 50 questions in 15 minutes.
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Match each statement with the correct term.
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This is a study tool. The 3 wrong answers for each question are randomly chosen from answers to other questions. So, you might find at times the answers obvious, but you will see it re-enforces your understanding as you take the test each time.

1. Manual Test for Nomality
Can't tell without a Range chart.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
The secondary characteristics of a product; "bells and whistles."
Central Limit Theorem

2. Process occurance ranking
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
68%
The primary operating characteristics of a product.
The House of Quality.

3. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
The cycle time required to meet demand.
Pleasing to the senses.
Variable.
Lean is waste reduction - Six Sigma is variation reduction.

4. In a regression - what does the standard error of the estimate tell you?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Supplier - input - process - output - customer.
Method developed by Ishikawa to graphically display the causes of any given problem
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

5. Simple Regression Analysis (one factor regression model)
= y = Beta(0) + Beta(1)X + epsilon y=dependent variable (response) x=independent variable (predictor of y) - epsilon=error component - Beta(not)=intersection. If data include zero - it represents the mean of the distribution of y when - x=0. It does
= yij - y(bar)i --> value minus sum of that treatment (of row)
Not necessarily.
Concluding there has not been an effect/change when there has.

6. What is the role of a green belt?
Kaoru Ishikawa.
Taguchi
A time series plot.
To be a member of a Six Sigma project team.

7. FMEA
Variable.
It looks to minimize the probability of a failure - or to minimize its effects
To do a capability study for a non-centered process.
A tool that shows performance along key dimensions all at once.

8. What is Value Stream Mapping?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
To do a capability study for a non-centered process.
Large enough to find two of the attribute - on average.
A tool that shows where there is waste in a process.

9. Non-random patterns (Run Charts)
Shifts - Trends - Repeating patterns - Correlation with known events
p-bar - the long-run percent defective.
F_alpha - df(tr) - df (error)
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

10. In Juran's Cost of Quality model - which categories of costs balance which other categories?
5%
Lean (or JIT).
Attribute.
Prevention and appraisal costs are balanced against internal and external failure.

11. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
The manager in charge of a process being improved in a Six Sigma project.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Another way to assess the significance of the analyzed factors is through a graphic procedure developed by C. Daniel when only one replicate (a single observation) was obtained:

12. What is FMEA?
Is the way in which the failure is manifested.
Failure Modes and Effects Analysis
The ratio of outputs to inputs; 1-scrap.
1) Identify the Range (Max Value - Min Value) 2) Determine # of bins 3) Determine the Width of each bin --> (Range / # Bins) 4) Put values in correct Bin

13. What is a Gage R&R?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
A tools that is used to measure the amount of variation in the measurement system arising from the measurement device (repeatability) and the people taking the measurement (reproducibility).
Through producer/consumer negotiation.
Define - measure - analyze - design - verify.

14. Taguchi's experimental designs are of this type.
Fitness for use.
Fractional factorial designs (orthogonal arrays)
Prevention and appraisal costs are balanced against internal and external failure.
It usually isn't possible to hold all other variables constant - There is no way to account for the effect of joint variation of independent variables - such as interaction - There is no way to account for experimental error - including measurement v

15. Disadvantages of DOE

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16. Failure cause
It's good -- but it's still out of control!
Not necessarily.
Is what induces the failure
A brainstorming tool that shows the connections between ideas.

17. Who first studied randomness in industrial processes
Large enough to find two of the attribute - on average.
Is the way in which the failure is manifested.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Walter A. Shewhart

18. What is a run chart?
Variable.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
A time series plot.
They move closer to the center line.

19. What are two other names for an Ishikawa diagram?
=sqrt((p*(1-p)/n)
Fishbone - cause-and-effect diagram.
Deming.
A brainstorming tool that shows the connections between ideas.

20. What is a network diagram?
Observed variation in response is caused by the input
Is the way in which the failure is manifested.
A diagram that shows the relationships between activities in a project network.
50%

21. Definition of Interaction
To obtain a certain desirable outcome from the process
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The gap between what management thinks customers want and what customers really want.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

22. Regression Analysis
Attribute.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Inventory = throughput x flow time.
95%

23. What is an affinity diagram?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A brainstorming tool that shows the connections between ideas.
The gap between what is promised and what is delivered.
=sqrt(Σ(x-x-bar)^2)/(n-1))

24. Daniel Test
The cycle time required to meet demand.
Another way to assess the significance of the analyzed factors is through a graphic procedure developed by C. Daniel when only one replicate (a single observation) was obtained:
= y = Beta(0) + Beta(1)X + epsilon y=dependent variable (response) x=independent variable (predictor of y) - epsilon=error component - Beta(not)=intersection. If data include zero - it represents the mean of the distribution of y when - x=0. It does
Variable.

25. Detection Criteria Ranking
Is the consequence of the failure.
X-bar-bar
10 if Almost impossible to detect
To manage the Six Sigma project.

26. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Fitness for use.
Financial - customer - internal process - innovation and learning.
Attribute
Failure Modes and Effects Analysis

27. What is the role of a black belt?
To manage the Six Sigma project.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Large enough to find two of the attribute - on average.
Mean time to failure.

28. What is poka yoke?
A random variable that summarizes the information from the sample(s).
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Is what induces the failure
Mistake-proofing.

29. Based on what principal can we use the normal distribution assumptions for SPC?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
p-bar - the long-run percent defective.
The Japanese national quality award.
Central Limit Theorem

30. If you have calculated a Cpk - should you also calculate a Cp?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
What the value of the dependent variable is when the independent variable is zero.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

31. List two appraisal costs.
Look for the assignable cause of non-random variation.
50%
F_alpha - df(tr) - df (error)
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

32. If a three-stage process has 90% yields at each stage - what is the overall yield?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Speed - courtesy - competence - and ease of repair.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
0.9^3 or 72.9%

33. What are the four categories of costs in Juran's framework?
Consumer risk.
Prevention - appraisal - internal failure - external failure.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

34. Define benchmarking.
Studying firms with the best performance in a particular area.
Workers - machines - materials.
A tool that shows where there is waste in a process.
A diagram that shows the relationships between activities in a project network.

35. Regression
Kaoru Ishikawa.
Represents the behavior of a process
Conformance to specifications.
The secondary characteristics of a product; "bells and whistles."

36. Who developed the fishbone diagram?
Shifts - Trends - Repeating patterns - Correlation with known events
False - because each machine will have different natural tolerances.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Kaoru Ishikawa.

37. The Test Statistic (TS)
Because the mean and standard deviation are independent of each other.
To manage the Six Sigma project.
Technical quality is the "what" of the service; functional quality is the "how."
A random variable that summarizes the information from the sample(s).

38. What type of risk is associated with Type 1 Error?
Workers - machines - materials.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
10 if Almost impossible to detect
Producer risk.

39. For what is a p-chart used?
To monitor a process when measurement by attribute is used.
Method developed by Ishikawa to graphically display the causes of any given problem
50%
Lower skill requirements - faster - less chance for error.

40. What percentage of a normal distribution lies above the mean?
50%
Sort - Set in Order - Shine - Standardize - Sustain
Taguchi
Lean (or JIT).

41. What is the center line of an X-bar chart?
X-bar-bar
Scrap - rework - retest - downtime - yield losses - disposition costs.
Another way to assess the significance of the analyzed factors is through a graphic procedure developed by C. Daniel when only one replicate (a single observation) was obtained:
A tools that is used to measure the amount of variation in the measurement system arising from the measurement device (repeatability) and the people taking the measurement (reproducibility).

42. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
5%
Represents the behavior of a process
68%
=sqrt((p*(1-p)/n)

43. You have been plotting sample means on an x-bar chart and all points indicate normal - expected variation. Is the process in control?

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44. For what is an x-bar chart used?
Causes that lead to a particular effect.
Conformance to specifications.
Shows the temporal flow of activities in a project network.
To monitor a process when measurement by variables is used.

45. What is the role of a master black belt?
To mentor/coach (and sometimes train) black belts.
= y = Beta(0) + Beta(1)X + epsilon y=dependent variable (response) x=independent variable (predictor of y) - epsilon=error component - Beta(not)=intersection. If data include zero - it represents the mean of the distribution of y when - x=0. It does
The gap between specifications and how service is performed.
10 for Hazardous without warning 1 for none

46. Define aesthetic quality.
Pleasing to the senses.
Workers - machines - materials.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Waste.

47. What is the formula for standard deviation?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Attribute
100%
=sqrt(Σ(x-x-bar)^2)/(n-1))

48. In the Service Quality Gap Model - what is Gap 2?
p-bar - the long-run percent defective.
The House of Quality.
10 if Almost impossible to detect
The gap between what management thinks customers want and the process specifications.

49. What quality tool formally incorporates the voice of the customer?
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
QFD
No -- if it is not the same - it can only be worse!
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

50. What is Kaizen?
Rapid improvement process.
It usually isn't possible to hold all other variables constant - There is no way to account for the effect of joint variation of independent variables - such as interaction - There is no way to account for experimental error - including measurement v
= y = Beta(0) + Beta(1)X + epsilon y=dependent variable (response) x=independent variable (predictor of y) - epsilon=error component - Beta(not)=intersection. If data include zero - it represents the mean of the distribution of y when - x=0. It does
Define - measure - analyze - design - verify.

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Six Sigma

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