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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. 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
Deming.
The gap between what customers expect and the service they receive.
68%

2. Creating a Run Chart
Prevention - appraisal - internal failure - external failure.
Attribute
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Mistake-proofing.

3. In a regression - what does the coefficient of the intercept tell you
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.
What the value of the dependent variable is when the independent variable is zero.
99.73%
Stratify a particular defect type according to logical criteria

4. List two components of internal failure.
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.
0.9^3 or 72.9%
No -- if it is not the same - it can only be worse!
Scrap - rework - retest - downtime - yield losses - disposition costs.

5. Name the structure associated with Quality Function Deployment.
QFD
Prevention - appraisal - internal failure - external failure.
Look for the assignable cause of non-random variation.
The House of Quality.

6. Which quality guru developed the concept of loss to society?
They move closer to the center line.
Variable.
Taguchi
50%

7. What is a spaghetti diagram?
The gap between what customers expect and the service they receive.
A tool that shows the physical flows through a space.
A descending order-sorted bar chart with a cumulative percentage line.
They move closer to the center line.

8. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Attribute.
Rapid improvement process.
Outside.
Causes that lead to a particular effect.

9. In a regression - what does the standard error of the estimate tell you?
Define - measure - analyze - improve - control.
Lean is waste reduction - Six Sigma is variation reduction.
95%
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

10. What is poka yoke?
3.4 (assuming 1.5 sigma shift in the mean)
Large enough to find two of the attribute - on average.
Mean time to failure.
Mistake-proofing.

11. How are LQL and AQL determined in an acceptance sampling plan?
Through producer/consumer negotiation.
Fewer good units to sell - increased variable cost/unit.
Studying firms with the best performance in a particular area.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

12. Process occurance ranking
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
99.73%
Inventory = throughput x flow time.
Upper control limit.

13. Define conformance quality.
1.Interactions can be detected and measured 2.Each value does the work of several values 3.Experimental error is quantified and used to determine the confidence the experimenter has in the conclusions
An assertion or conjecture concerning one or more populations
The degree to which a product meets pre-established standards.
The gap between specifications and how service is performed.

14. What quality guru emphasizes management as a system?
Causes that lead to a particular effect.
The cycle time required to meet demand.
Deming.
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.

15. Define aesthetic quality.
1.Interactions can be detected and measured 2.Each value does the work of several values 3.Experimental error is quantified and used to determine the confidence the experimenter has in the conclusions
Pleasing to the senses.
Shifts - Trends - Repeating patterns - Correlation with known events
Brand image.

16. A process is operating "in control." Does this mean the customer's requirements are met?
Large enough to find two of the attribute - on average.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
No -- only if the process is also capable.
Different types of defects are listed (used for Pareto chart)

17. Define yield.
The cycle time required to meet demand.
The ratio of outputs to inputs; 1-scrap.
Causes that lead to a particular effect.
95%

18. 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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19. What does a project prioritization matrix do?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
=sqrt(Σ(x-x-bar)^2)/(n-1))
The Japanese national quality award.
Assigns scores to weighted criteria for each project under consideration.

20. In the Service Quality Gap Model - what is Gap 3?
The gap between specifications and how service is performed.
To monitor a process when measurement by attribute is used.
The primary operating characteristics of a product.
Before production starts

21. What is a CAVE man?
Speed - courtesy - competence - and ease of repair.
The Japanese national quality award.
Someone who is consistently against virtually everything.
The ratio of outputs to inputs; 1-scrap.

22. What does SIPOC stand for?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Is the consequence of the failure.
Prevention and appraisal costs are balanced against internal and external failure.
Supplier - input - process - output - customer.

23. TWO-DIMENTIONAL SCATTER PLOT
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Consumer risk.
A scatterplot.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

24. If you have calculated a Cpk - should you also calculate a Cp?
Different types of defects are listed (used for Pareto chart)
Shows the temporal flow of activities in a project network.
Deming.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

25. What are the 5 Ss?
Sort - Set in Order - Shine - Standardize - Sustain
The number of standard deviations some value is from the mean.
Defects Per Million Opportunities
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

26. For what is a p-chart used?
To monitor a process when measurement by attribute is used.
95%
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
0.9^3 or 72.9%

27. What are the three main categories of assignable cause?
Taguchi
Workers - machines - materials.
Used to create frequency distribution tally sheets
99.73%

28. Explain the difference between technical and functional service quality.
To be a member of a Six Sigma project team.
Waste.
Technical quality is the "what" of the service; functional quality is the "how."
Failure Modes and Effects Analysis

29. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Is the consequence of the failure.
99.73%
100%
Conformance to specifications.

30. To what does the Six in Six Sigma relate?
Walter A. Shewhart
The target number of standard deviations from the mean for specifications.
Fewer good units to sell - increased variable cost/unit.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

31. ANOVA

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32. Taguchi's experimental designs are of this type.
Fractional factorial designs (orthogonal arrays)
Defects Per Million Opportunities
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Represents the behavior of a process

33. Define durability.
Mean time to replacement.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Organize ideas into meaningful categories by recognizing their underlying similarity
= yij - y(bar)i --> value minus sum of that treatment (of row)

34. What is Type 1 Error?
Central Limit Theorem
Lower skill requirements - faster - less chance for error.
Concluding there has been an effect/change when there has not.
X-bar-bar

35. What is a run chart?
A tool that shows the physical flows through a space.
A time series plot.
Initiated before or at design concept finalization
Stratify a particular defect type according to logical criteria

36. Test for Independence
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
0.9^3 or 72.9%
Waste.
The gap between what management thinks customers want and what customers really want.

37. Manual Test for Nomality
The secondary characteristics of a product; "bells and whistles."
To mentor/coach (and sometimes train) black belts.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Different types of defects are listed (used for Pareto chart)

38. In the Service Quality Gap Model - what is Gap 5?
Variable.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The gap between what customers expect and the service they receive.
Taguchi

39. List two appraisal costs.
What the value of the dependent variable is when the independent variable is zero.
The degree to which a product meets pre-established standards.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Shows the temporal flow of activities in a project network.

40. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Hold all input variables constant except one. Observe the response as you vary the single input.
Lower skill requirements - faster - less chance for error.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The US national quality award.

41. What is Jidoka?
Controlling quality at the source.
Attribute.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
10 if Almost impossible to detect

42. Complete this quality phrase: 'Fix the process - not the _____.'
Blame.
A brainstorming tool that shows the connections between ideas.
A random variable that summarizes the information from the sample(s).
Supplier - input - process - output - customer.

43. What is DPMO?
Defects Per Million Opportunities
Technical quality is the "what" of the service; functional quality is the "how."
The gap between what management thinks customers want and the process specifications.
Prevention - appraisal - internal failure - external failure.

44. Pareto Analysis
= yij - y(bar)i --> value minus sum of that treatment (of row)
Is what induces the failure
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Kaoru Ishikawa.

45. What size should samples be for attribute SPC?
Defects Per Million Opportunities
Large enough to find two of the attribute - on average.
Fishbone - cause-and-effect diagram.
The gap between what is promised and what is delivered.

46. What is a Pareto chart?
0.9^3 or 72.9%
A descending order-sorted bar chart with a cumulative percentage line.
Organize ideas into meaningful categories by recognizing their underlying similarity
No -- the variation also has to be random and "expected."

47. Defect location check sheets
Variable.
Used to create frequency distribution tally sheets
Linearity - normality - homoscedasticity - independence.
Actual drawings - layouts - maps - etc which show where a defect occurs

48. With Six Sigma capability - how many defects per million opportunities would you see?
Observed variation in response is caused by the input
3.4 (assuming 1.5 sigma shift in the mean)
Someone who is consistently against virtually everything.
The gap between specifications and how service is performed.

49. In the Service Quality Gap Model - what is Gap 1?
Speed - courtesy - competence - and ease of repair.
Shows the temporal flow of activities in a project network.
The gap between what management thinks customers want and what customers really want.
Pleasing to the senses.

50. List two components of prevention cost.
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
Mean time to replacement.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Supplier - input - process - output - customer.

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