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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. In a regression - what does the p value of F tell you?
An assertion or conjecture concerning one or more populations
5%
Taguchi
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).

2. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Sampling for SPC is done real time.
Workers - machines - materials.
It looks to minimize the probability of a failure - or to minimize its effects

3. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Is the consequence of the failure.
The degree to which a product meets pre-established standards.
They move closer to the center line.
99.73%

4. If you have calculated a Cpk - should you also calculate a Cp?
Is the consequence of the failure.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
The gap between what is promised and what is delivered.
Brand image.

5. What is Jidoka?
Controlling quality at the source.
To be a member of a Six Sigma project team.
Concluding there has been an effect/change when there has not.
The gap between what management thinks customers want and the process specifications.

6. Risk Priority Number RPN
10 for Hazardous without warning 1 for none
Failure Modes and Effects Analysis
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Lean (or JIT).

7. Pareto Analysis
10 if Almost impossible to detect
Pleasing to the senses.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
A tool that shows performance along key dimensions all at once.

8. Define performance quality.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
QFD
Causes that lead to a particular effect.
The primary operating characteristics of a product.

9. In the Service Quality Gap Model - what is Gap 1?
To mentor/coach (and sometimes train) black belts.
It looks to minimize the probability of a failure - or to minimize its effects
Assigns scores to weighted criteria for each project under consideration.
The gap between what management thinks customers want and what customers really want.

10. Stratified defect check sheets
Stratify a particular defect type according to logical criteria
Different types of defects are listed (used for Pareto chart)
Attribute
= 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

11. Why do you need two control charts for variables SPC?
The gap between what management thinks customers want and what customers really want.
Because the mean and standard deviation are independent of each other.
No -- the variation also has to be random and "expected."
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

12. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
The number of standard deviations some value is from the mean.
Conformance to specifications.
Stratify a particular defect type according to logical criteria

13. What is the center line of an X-bar chart?
Deming.
X-bar-bar
An assertion or conjecture concerning one or more populations
Fitness for use.

14. What is the role of a green belt?
To be a member of a Six Sigma project team.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Shifts - Trends - Repeating patterns - Correlation with known events
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

15. Disadvantages of DOE

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16. When is Cpk used?
Method developed by Ishikawa to graphically display the causes of any given problem
Lower control limit.
To do a capability study for a non-centered process.
They move closer to the center line.

17. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Causes that lead to a particular effect.
=sqrt((p*(1-p)/n)

18. The Test Statistic (TS)
A random variable that summarizes the information from the sample(s).
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Represents the behavior of a process
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

19. Define conformance quality.
Fractional factorial designs (orthogonal arrays)
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
The degree to which a product meets pre-established standards.
Observed variation in response is caused by the input

20. Test for constant variance
Fishbone - cause-and-effect diagram.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
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.
Sort - Set in Order - Shine - Standardize - Sustain

21. Define aesthetic quality.
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.
Pleasing to the senses.
Define - measure - analyze - design - verify.
Defects Per Million Opportunities

22. What is a run chart?
99.73%
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
To be a member of a Six Sigma project team.
A time series plot.

23. In the Service Quality Gap Model - what is Gap 4?
Financial - customer - internal process - innovation and learning.
The gap between what is promised and what is delivered.
Is the consequence of the failure.
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

24. There are two milling machines in the shop. Data has been collected on one to compute control limits for both. This is acceptable SPC practice - true or false and why?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
False - because each machine will have different natural tolerances.
Can't tell without a Range chart.
The secondary characteristics of a product; "bells and whistles."

25. Define takt time.
The cycle time required to meet demand.
Waste.
Lean (or JIT).
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

26. What is the difference between the way sampling is done for SPC and for acceptance sampling?
The gap between specifications and how service is performed.
Producer risk.
Pleasing to the senses.
Sampling for SPC is done real time.

27. What is the 5S model?
Inventory = throughput x flow time.
Lean (or JIT).
A brainstorming tool that shows the connections between ideas.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

28. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
Variable.
They move closer to the center line.
X-bar-bar

29. In a Z table - what is Z?
Represents the behavior of a process
The number of standard deviations some value is from the mean.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Look for the assignable cause of non-random variation.

30. What is the center line of a p-chart?
Shows the temporal flow of activities in a project network.
Because the mean and standard deviation are independent of each other.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
p-bar - the long-run percent defective.

31. What is the role of a black belt?
Actual drawings - layouts - maps - etc which show where a defect occurs
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
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.
To manage the Six Sigma project.

32. What is Little's Law?
Inventory = throughput x flow time.
Used to create frequency distribution tally sheets
A brainstorming tool that shows the connections between ideas.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

33. Non-random patterns (Run Charts)
The manager in charge of a process being improved in a Six Sigma project.
Walter A. Shewhart
Variable.
Shifts - Trends - Repeating patterns - Correlation with known events

34. What is Value Stream Mapping?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
A tool that shows where there is waste in a process.
Prevention and appraisal costs are balanced against internal and external failure.
Controlling quality at the source.

35. What is a Gage R&R?
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).
= yij - y(bar)i --> value minus sum of that treatment (of row)
Producer risk.
Variable.

36. What is DPMO?
Large enough to find two of the attribute - on average.
Defects Per Million Opportunities
Rapid improvement process.
The gap between what management thinks customers want and what customers really want.

37. What are the four regression assumptions?
Organize ideas into meaningful categories by recognizing their underlying similarity
Lean is waste reduction - Six Sigma is variation reduction.
Linearity - normality - homoscedasticity - independence.
100%

38. Residual
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A tool that shows where there is waste in a process.
The US national quality award.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

39. Define features.
The secondary characteristics of a product; "bells and whistles."
To mentor/coach (and sometimes train) black belts.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
95%

40. Affinity Diagrams
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Upper control limit.

41. What does Crosby say about benchmarking?
Not necessarily.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

42. Affinity Diagrams
Lower skill requirements - faster - less chance for error.
Organize ideas into meaningful categories by recognizing their underlying similarity
The primary operating characteristics of a product.
Through producer/consumer negotiation.

43. What are the four categories of costs in Juran's framework?
Blame.
Variable.
Prevention - appraisal - internal failure - external failure.
Is the way in which the failure is manifested.

44. If a three-stage process has 90% yields at each stage - what is the overall yield?
Used to create frequency distribution tally sheets
0.9^3 or 72.9%
= yij - y(bar)i --> value minus sum of that treatment (of row)
Large enough to find two of the attribute - on average.

45. What is process capability?
95%
To be a member of a Six Sigma project team.
The ability of a process to consistently meet customer specifications.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

46. What is CTQ?
Stratify a particular defect type according to logical criteria
No -- the variation also has to be random and "expected."
Sort - Set in Order - Shine - Standardize - Sustain
Critical to quality.

47. What is an affinity diagram?
A brainstorming tool that shows the connections between ideas.
Blame.
Central Limit Theorem
Actual drawings - layouts - maps - etc which show where a defect occurs

48. What is the Deming Prize?
A time series plot.
99.73%
The Japanese national quality award.
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).

49. 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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50. What quality tool formally incorporates the voice of the customer?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Mean time to failure.
Sampling for SPC is done real time.
QFD

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