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Six Sigma

Subjects : certifications, six-sigma, business-skills

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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. Who developed the fishbone diagram?
It's good -- but it's still out of control!
Kaoru Ishikawa.
A tool that shows the physical flows through a space.
Causes that lead to a particular effect.

2. Define aesthetic quality.
Pleasing to the senses.
Causes that lead to a particular effect.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
10 for Hazardous without warning 1 for none

3. What is Little's Law?
A descending order-sorted bar chart with a cumulative percentage line.
Kaoru Ishikawa.
Inventory = throughput x flow time.
Supplier - input - process - output - customer.

4. Define yield.
The gap between what customers expect and the service they receive.
The degree to which a product meets pre-established standards.
The ratio of outputs to inputs; 1-scrap.
Failure Modes and Effects Analysis

5. Failure effect
Is the consequence of the failure.
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
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
= 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

6. What is a histogram?
The gap between what management thinks customers want and the process specifications.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
To monitor a process when measurement by variables is used.
It's good -- but it's still out of control!

7. What is DPMO?
Variable.
Because the mean and standard deviation are independent of each other.
Defects Per Million Opportunities
They move closer to the center line.

8. What is Value Stream Mapping?
Kaoru Ishikawa.
A tool that shows where there is waste in a process.
A scatterplot.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

9. What does SIPOC stand for?
Taguchi
Linearity - normality - homoscedasticity - independence.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Supplier - input - process - output - customer.

10. Cause and Effect Diagrams
A tool that shows where there is waste in a process.
Method developed by Ishikawa to graphically display the causes of any given problem
Blame.
Producer risk.

11. FMEA
The cycle time required to meet demand.
Prevention - appraisal - internal failure - external failure.
An assertion or conjecture concerning one or more populations
It looks to minimize the probability of a failure - or to minimize its effects

12. Based on what principal can we use the normal distribution assumptions for SPC?
The gap between what is promised and what is delivered.
Lean is waste reduction - Six Sigma is variation reduction.
Central Limit Theorem
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

13. What is the Deming Prize?
X-bar-bar
Decomposing the total variation of data into: (a) the internal or "natural" or "within" groups variation - and (b) the "between" groups variation in such a way that when these two types of variation are compared - it's possible to determine if there
Blame.
The Japanese national quality award.

14. What happens to control limits on an SPC chart when sample size is increased?
The gap between what management thinks customers want and what customers really want.
The target number of standard deviations from the mean for specifications.
They move closer to the center line.
Fewer good units to sell - increased variable cost/unit.

15. What is the difference between the way sampling is done for SPC and for acceptance sampling?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Sampling for SPC is done real time.
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
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:

16. Effect ranking (Severity of the Defect)
The gap between specifications and how service is performed.
Supplier - input - process - output - customer.
To be a member of a Six Sigma project team.
10 for Hazardous without warning 1 for none

17. What is poka yoke?
Mistake-proofing.
Defects Per Million Opportunities
Because the mean and standard deviation are independent of each other.
The House of Quality.

18. Test for constant variance
Plot the residuals vs. the fitted values (mean of each group - y(hat) = y (bar)i ) - Assumption of ____________not rejected if the dispersion of every group is approximately the same.
p-bar - the long-run percent defective.
To mentor/coach (and sometimes train) black belts.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

19. The Test Statistic (TS)
X-bar-bar
A tool that shows performance along key dimensions all at once.
A random variable that summarizes the information from the sample(s).
An assertion or conjecture concerning one or more populations

20. Affinity Diagrams
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Organize ideas into meaningful categories by recognizing their underlying similarity
Variable.
Is the way in which the failure is manifested.

21. What is Jidoka?
Controlling quality at the source.
The gap between what management thinks customers want and what customers really want.
Organize ideas into meaningful categories by recognizing their underlying similarity
Actual drawings - layouts - maps - etc which show where a defect occurs

22. What is the center line of an X-bar chart?
Producer risk.
An assertion or conjecture concerning one or more populations
Sampling for SPC is done real time.
X-bar-bar

23. One factor at a time (OFAT)
The degree to which a product meets pre-established standards.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Observed variation in response is caused by the input
Pleasing to the senses.

24. What type of risk is associated with Type II Error?
Mistake-proofing.
The gap between specifications and how service is performed.
Consumer risk.
Sampling for SPC is done real time.

25. Define takt time.
Shows the temporal flow of activities in a project network.
The Japanese national quality award.
The cycle time required to meet demand.
To do a capability study for a non-centered process.

26. List two components of prevention cost.
Large enough to find two of the attribute - on average.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The number of standard deviations some value is from the mean.

27. In Juran's Cost of Quality model - which categories of costs balance which other categories?
An assertion or conjecture concerning one or more populations
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
5%
Prevention and appraisal costs are balanced against internal and external failure.

28. Residual(eij)
= yij - y(bar)i --> value minus sum of that treatment (of row)
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

29. What is muda
The ability of a process to consistently meet customer specifications.
Waste.
Because the mean and standard deviation are independent of each other.
The primary operating characteristics of a product.

30. Residual
The gap between what customers expect and the service they receive.
Linearity - normality - homoscedasticity - independence.
The gap between what management thinks customers want and the process specifications.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

31. What is a dashboard?
No -- if it is not the same - it can only be worse!
A tool that shows performance along key dimensions all at once.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Is the consequence of the failure.

32. Define perceived quality (Garvin's framework).
Central Limit Theorem
Brand image.
What the value of the dependent variable is when the independent variable is zero.
How likely it is to have an F statistic of that value if there really is no relationship between the dependent variable and the independent variable(s).

33. In the Service Quality Gap Model - what is Gap 5?
The degree to which a product meets pre-established standards.
Different types of defects are listed (used for Pareto chart)
The gap between what customers expect and the service they receive.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

34. DFMEA
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Initiated before or at design concept finalization
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
The Japanese national quality award.

35. Failure cause
Define - measure - analyze - design - verify.
Speed - courtesy - competence - and ease of repair.
Is what induces the 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

36. Uses of regression - Control
To obtain a certain desirable outcome from the process
Walter A. Shewhart
Fractional factorial designs (orthogonal arrays)
Causes that lead to a particular effect.

37. Explain the difference between technical and functional service quality.
Hold all input variables constant except one. Observe the response as you vary the single input.
Producer risk.
Studying firms with the best performance in a particular area.
Technical quality is the "what" of the service; functional quality is the "how."

38. For what is an x-bar chart used?
To monitor a process when measurement by variables is used.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Stratify a particular defect type according to logical criteria
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

39. Define features.
The secondary characteristics of a product; "bells and whistles."
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

40. Define product reliability.
Waste.
Mean time to failure.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

41. One factor at a time (OFAT)
Scrap - rework - retest - downtime - yield losses - disposition costs.
Hold all input variables constant except one. Observe the response as you vary the single input.
Mistake-proofing.
3.4 (assuming 1.5 sigma shift in the mean)

42. What is the formula for standard deviation?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
To do a capability study for a non-centered process.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Through producer/consumer negotiation.

43. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Variable.
=sqrt(Σ(x-x-bar)^2)/(n-1))
To do a capability study for a non-centered process.
Defects Per Million Opportunities

44. F value
The manager in charge of a process being improved in a Six Sigma project.
Kaoru Ishikawa.
F_alpha - df(tr) - df (error)
Blame.

45. Define durability.
Waste.
Mean time to replacement.
Attribute
A brainstorming tool that shows the connections between ideas.

46. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
The House of Quality.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Fewer good units to sell - increased variable cost/unit.
Attribute

47. Daniel Test
= 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
Different types of defects are listed (used for Pareto chart)
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:
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

48. How are LQL and AQL determined in an acceptance sampling plan?
Brand image.
Lower skill requirements - faster - less chance for error.
Through producer/consumer negotiation.
The ability of a process to consistently meet customer specifications.

49. What is FMEA?
Observed variation in response is caused by the input
It looks to minimize the probability of a failure - or to minimize its effects
Define - measure - analyze - design - verify.
Failure Modes and Effects Analysis

50. When is Cpk used?
consists of plotting the residuals vs. the order of each experiment - If - as in the case of the constant variance a random horizontal band is obtained - the ______________ of the residuals is not rejected. (should be random above a below the line i
To do a capability study for a non-centered process.
Mistake-proofing.
Prevention and appraisal costs are balanced against internal and external failure.

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