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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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1. Definition of Interaction
Variable.
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
=sqrt((p*(1-p)/n)
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

2. What quality tool formally incorporates the voice of the customer?
99.73%
Prevention and appraisal costs are balanced against internal and external failure.
QFD
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

3. For what is a p-chart used?
To monitor a process when measurement by attribute is used.
Rapid improvement process.
To manage the Six Sigma project.
Not necessarily.

4. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
The gap between what management thinks customers want and what customers really want.
Outside.
Large enough to find two of the attribute - on average.
Attribute

5. What is a network diagram?
A diagram that shows the relationships between activities in a project network.
QFD
Sort - Set in Order - Shine - Standardize - Sustain
10 for Hazardous without warning 1 for none

6. Who is a process owner?
The gap between specifications and how service is performed.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
The manager in charge of a process being improved in a Six Sigma project.
The gap between what management thinks customers want and what customers really want.

7. Detection Criteria Ranking
10 if Almost impossible to detect
Kaoru Ishikawa.
Look for the assignable cause of non-random variation.
Brand image.

8. What is Little's Law?
Inventory = throughput x flow time.
Waste.
Walter A. Shewhart
Initiated before or at design concept finalization

9. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Workers - machines - materials.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
5%
If the Response vs. Levels graph if the response lines are not parallel (crossing)

10. When is Cpk used?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
To monitor a process when measurement by attribute is used.
To do a capability study for a non-centered process.

11. What happens to control limits on an SPC chart when sample size is increased?
They move closer to the center line.
Lean is waste reduction - Six Sigma is variation reduction.
A tool that shows where there is waste in a process.
Mean time to replacement.

12. What is the role of a black belt?
Central Limit Theorem
10 if Almost impossible to detect
To manage the Six Sigma project.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

13. Define features.
Fewer good units to sell - increased variable cost/unit.
The gap between what management thinks customers want and what customers really want.
Is the way in which the failure is manifested.
The secondary characteristics of a product; "bells and whistles."

14. Stratified defect check sheets
What the value of the dependent variable is when the independent variable is zero.
Stratify a particular defect type according to logical criteria
It's good -- but it's still out of control!
Kaoru Ishikawa.

15. In Juran's Cost of Quality model - which categories of costs balance which other categories?
It's good -- but it's still out of control!
Prevention and appraisal costs are balanced against internal and external failure.
Shows the temporal flow of activities in a project network.
A tool that shows where there is waste in a process.

16. Pareto Analysis
A diagram that shows the relationships between activities in a project network.
Fractional factorial designs (orthogonal arrays)
100%
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

17. What is the Deming Prize?
The Japanese national quality award.
Waste.
Hold all input variables constant except one. Observe the response as you vary the single input.
To be a member of a Six Sigma project team.

18. Test for Independence
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
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
=sqrt(Σ(x-x-bar)^2)/(n-1))
Hold all input variables constant except one. Observe the response as you vary the single input.

19. Name the structure associated with Quality Function Deployment.
Lower control limit.
The House of Quality.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Define - measure - analyze - improve - control.

20. Who developed the fishbone diagram?
Kaoru Ishikawa.
Taguchi
Scrap - rework - retest - downtime - yield losses - disposition costs.
Organize ideas into meaningful categories by recognizing their underlying similarity

21. In the Service Quality Gap Model - what is Gap 5?
They move closer to the center line.
False - because each machine will have different natural tolerances.
Controlling quality at the source.
The gap between what customers expect and the service they receive.

22. ANOVA

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23. Complete this quality phrase: 'Fix the process - not the _____.'
Blame.
Workers - machines - materials.
Lower skill requirements - faster - less chance for error.
A brainstorming tool that shows the connections between ideas.

24. Failure Mode
A descending order-sorted bar chart with a cumulative percentage line.
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).
Fractional factorial designs (orthogonal arrays)
Is the way in which the failure is manifested.

25. What is the formula for the standard deviation of a proportion?
Organize ideas into meaningful categories by recognizing their underlying similarity
Lean (or JIT).
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.
=sqrt((p*(1-p)/n)

26. Which quality guru developed the concept of loss to society?
Fishbone - cause-and-effect diagram.
Lean (or JIT).
A random variable that summarizes the information from the sample(s).
Taguchi

27. What is a Gantt chart?
Shows the temporal flow of activities in a project network.
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
Attribute
Mean time to replacement.

28. Process check sheets
To monitor a process when measurement by variables is used.
68%
Used to create frequency distribution tally sheets
The gap between what management thinks customers want and the process specifications.

29. If you can only collect categorical data - what type of SPC charting can you do?
Supplier - input - process - output - customer.
Lower skill requirements - faster - less chance for error.
Prevention and appraisal costs are balanced against internal and external failure.
Attribute.

30. DFMEA
Before production starts
Initiated before or at design concept finalization
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:
Organize ideas into meaningful categories by recognizing their underlying similarity

31. What is the center line of an X-bar chart?
50%
=sqrt((p*(1-p)/n)
Attribute
X-bar-bar

32. How does Juran define quality?
The gap between what management thinks customers want and the process specifications.
10 if Almost impossible to detect
Fitness for use.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

33. In a Z table - what is Z?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
It looks to minimize the probability of a failure - or to minimize its effects
Causes that lead to a particular effect.
The number of standard deviations some value is from the mean.

34. Statistical Hypothesis
An assertion or conjecture concerning one or more populations
Lean (or JIT).
No -- if it is not the same - it can only be worse!
It looks to minimize the probability of a failure - or to minimize its effects

35. In a regression - what does the p value of F tell you?
Speed - courtesy - competence - and ease of repair.
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).
A systemized group of activities designed to 1. recognize and evaluate the potential failure of product/process and its effects 2. Identify actions which could eliminate or reduce the chance of potential failure ocurring 3. document the process
3.4 (assuming 1.5 sigma shift in the mean)

36. What is poka yoke?
68%
Inventory = throughput x flow time.
Mistake-proofing.
99.73%

37. Creating a Run Chart
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Shifts - Trends - Repeating patterns - Correlation with known events
Technical quality is the "what" of the service; functional quality is the "how."
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

38. Define durability.
Mean time to replacement.
Deming.
Lower control limit.
Method developed by Ishikawa to graphically display the causes of any given problem

39. List two components of internal failure.
X-bar-bar
The degree to which a product meets pre-established standards.
Defects Per Million Opportunities
Scrap - rework - retest - downtime - yield losses - disposition costs.

40. What does the abbreviation LCL stand for?
Sort - Set in Order - Shine - Standardize - Sustain
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Lower control limit.

41. Risk Priority Number RPN
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
An assertion or conjecture concerning one or more populations
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Sampling for SPC is done real time.

42. What is the formula for standard deviation?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The ratio of outputs to inputs; 1-scrap.
=sqrt(Σ(x-x-bar)^2)/(n-1))
The degree to which a product meets pre-established standards.

43. If you have calculated a Cpk - should you also calculate a Cp?
To monitor a process when measurement by variables is used.
Attribute.
Can't tell without a Range chart.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

44. Effect ranking (Severity of the Defect)
10 for Hazardous without warning 1 for none
Mean time to replacement.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

45. What are the Five Dimensions of Service Quality?
Fewer good units to sell - increased variable cost/unit.
Not necessarily.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

46. Advantages of DOE
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
The cycle time required to meet demand.
No -- only if the process is also capable.
Deming.

47. Affinity Diagrams
The degree to which a product meets pre-established standards.
Producer risk.
Organize ideas into meaningful categories by recognizing their underlying similarity
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

48. What does SIPOC stand for?
A descending order-sorted bar chart with a cumulative percentage line.
Causes that lead to a particular effect.
Supplier - input - process - output - customer.
Blame.

49. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Linearity - normality - homoscedasticity - independence.
Walter A. Shewhart
Lower skill requirements - faster - less chance for error.
68%

50. 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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Six Sigma

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