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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. What type of risk is associated with Type 1 Error?
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
The gap between what customers expect and the service they receive.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Producer risk.

2. DFMEA
Initiated before or at design concept finalization
To monitor a process when measurement by attribute is used.
To do a capability study for a non-centered process.
3.4 (assuming 1.5 sigma shift in the mean)

3. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
Assigns scores to weighted criteria for each project under consideration.
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
The gap between what management thinks customers want and what customers really want.

4. Which type of SPC measurement is more precise - variable or attribute?
Rapid improvement process.
Variable.
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
Conformance to specifications.

5. What does SIPOC stand for?
The gap between what customers expect and the service they receive.
A tool that shows where there is waste in a process.
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).
Supplier - input - process - output - customer.

6. DOE
A descending order-sorted bar chart with a cumulative percentage line.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Shows the temporal flow of activities in a project network.
They move closer to the center line.

7. What graphical tool is used to show the relationship between two numerical variables?
A scatterplot.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Hold all input variables constant except one. Observe the response as you vary the single input.
= yij - y(bar)i --> value minus sum of that treatment (of row)

8. Manual Test for Nomality
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Large enough to find two of the attribute - on average.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
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).

9. In the Service Quality Gap Model - what is Gap 4?
The gap between what is promised and what is delivered.
Method developed by Ishikawa to graphically display the causes of any given problem
Kaoru Ishikawa.
Look for the assignable cause of non-random variation.

10. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Mean time to replacement.
Supplier - input - process - output - customer.
Sampling for SPC is done real time.
Outside.

11. What are the four perspectives of the Balanced Scorecard?
Technical quality is the "what" of the service; functional quality is the "how."
Financial - customer - internal process - innovation and learning.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
= yij - y(bar)i --> value minus sum of that treatment (of row)

12. 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.
No -- only if the process is also capable.
Inventory = throughput x flow time.
A brainstorming tool that shows the connections between ideas.

13. What is process capability?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Is the way in which the failure is manifested.
The ability of a process to consistently meet customer specifications.
To mentor/coach (and sometimes train) black belts.

14. In a regression - what does the p value of F tell you?
Technical quality is the "what" of the service; functional quality is the "how."
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).
Waste.
Look for the assignable cause of non-random variation.

15. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Waste.
5%
What the value of the dependent variable is when the independent variable is zero.

16. What is a Pareto chart?
Waste.
Large enough to find two of the attribute - on average.
A descending order-sorted bar chart with a cumulative percentage line.
To monitor a process when measurement by attribute is used.

17. What is the Baldrige Award?
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.
Scrap - rework - retest - downtime - yield losses - disposition costs.
The US national quality award.
Defects Per Million Opportunities

18. List two appraisal costs.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Define - measure - analyze - improve - control.
To do a capability study for a non-centered process.
Shifts - Trends - Repeating patterns - Correlation with known events

19. One factor at a time (OFAT)
The Japanese national quality award.
Critical to quality.
Observed variation in response is caused by the input
Brand image.

20. Failure cause
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
A tool that shows the physical flows through a space.
Lower skill requirements - faster - less chance for error.

21. What is a spaghetti diagram?
Attribute.
Fewer good units to sell - increased variable cost/unit.
Look for the assignable cause of non-random variation.
A tool that shows the physical flows through a space.

22. In a regression - what does the standard error of the estimate tell you?
Studying firms with the best performance in a particular area.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Shifts - Trends - Repeating patterns - Correlation with known events
Is the way in which the failure is manifested.

23. What is a network diagram?
Attribute
Critical to quality.
A diagram that shows the relationships between activities in a project network.
X-bar-bar

24. What quality tool formally incorporates the voice of the customer?
QFD
The secondary characteristics of a product; "bells and whistles."
Can't tell without a Range chart.
5%

25. Definition of Interaction
Before production starts
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Someone who is consistently against virtually everything.
What the value of the dependent variable is when the independent variable is zero.

26. What do you do when a process is out of control?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
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
Look for the assignable cause of non-random variation.
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

27. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Defects Per Million Opportunities
Financial - customer - internal process - innovation and learning.
Lower skill requirements - faster - less chance for error.
Mistake-proofing.

28. When is Cpk used?
To do a capability study for a non-centered process.
The degree to which a product meets pre-established standards.
Producer risk.
10 if Almost impossible to detect

29. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
5%
Speed - courtesy - competence - and ease of repair.
Lean (or JIT).
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

30. TWO-DIMENTIONAL SCATTER PLOT
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Is the way in which the failure is manifested.
A scatterplot.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

31. Define serviceability.
Speed - courtesy - competence - and ease of repair.
Lean (or JIT).
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
0.9^3 or 72.9%

32. What is a CAVE man?
Is the way in which the failure is manifested.
Someone who is consistently against virtually everything.
Upper control limit.
Lower skill requirements - faster - less chance for error.

33. Explain the difference between technical and functional service quality.
Prevention and appraisal costs are balanced against internal and external failure.
Technical quality is the "what" of the service; functional quality is the "how."
Fewer good units to sell - increased variable cost/unit.
To monitor a process when measurement by variables is used.

34. In the Service Quality Gap Model - what is Gap 2?
Actual drawings - layouts - maps - etc which show where a defect occurs
The gap between what management thinks customers want and the process specifications.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Can't tell without a Range chart.

35. Creating a Run Chart
Concluding there has not been an effect/change when there has.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Upper control limit.
Shifts - Trends - Repeating patterns - Correlation with known events

36. What does DMAIC stand for?
Outside.
Define - measure - analyze - improve - control.
= yij - y(bar)i --> value minus sum of that treatment (of row)
QFD

37. A process is operating "in control." Does this mean the customer's requirements are met?
A tool that shows where there is waste in a process.
Method developed by Ishikawa to graphically display the causes of any given problem
No -- only if the process is also capable.
The US national quality award.

38. Non-random patterns (Run Charts)
The ratio of outputs to inputs; 1-scrap.
Shifts - Trends - Repeating patterns - Correlation with known events
Controlling quality at the source.
Waste.

39. What are the four categories of costs in Juran's framework?
Prevention - appraisal - internal failure - external failure.
Fitness for use.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
No -- only if the process is also capable.

40. What is the center line of a p-chart?
p-bar - the long-run percent defective.
0.9^3 or 72.9%
A time series plot.
What the value of the dependent variable is when the independent variable is zero.

41. What is FMEA?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
The number of standard deviations some value is from the mean.
Failure Modes and Effects Analysis
Define - measure - analyze - improve - control.

42. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
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
Is what induces the failure
Deming.
No -- the variation also has to be random and "expected."

43. In a Z table - what is Z?
Is the consequence of the failure.
A diagram that shows the relationships between activities in a project network.
The number of standard deviations some value is from the mean.
Speed - courtesy - competence - and ease of repair.

44. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Variable.
99.73%
Actual drawings - layouts - maps - etc which show where a defect occurs
A diagram that shows the relationships between activities in a project network.

45. How does Juran define quality?
Fitness for use.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Large enough to find two of the attribute - on average.
Someone who is consistently against virtually everything.

46. What is DMADV?
The House of Quality.
Define - measure - analyze - design - verify.
Workers - machines - materials.
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

47. Cause and Effect Diagrams
Because the mean and standard deviation are independent of each other.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Method developed by Ishikawa to graphically display the causes of any given problem

48. What is Kaizen?
Rapid improvement process.
Critical to quality.
99.73%
Workers - machines - materials.

49. Simple Regression Analysis (one factor regression model)
Represents the behavior of a process
Lean is waste reduction - Six Sigma is variation reduction.
Pleasing to the senses.
= 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

50. Test for Independence
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
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
Fishbone - cause-and-effect diagram.
Mean time to replacement.

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