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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.
Don't refresh. All questions and answers are randomly picked and ordered every time you load a test.

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. Non-random patterns (Run Charts)
The House of Quality.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Shifts - Trends - Repeating patterns - Correlation with known events
No -- the variation also has to be random and "expected."

2. What is Jidoka?
Fishbone - cause-and-effect diagram.
Controlling quality at the source.
Represents the behavior of a process
Is the consequence of the failure.

3. What is process capability?
The ability of a process to consistently meet customer specifications.
A tool that shows the physical flows through a space.
Organize ideas into meaningful categories by recognizing their underlying similarity
The manager in charge of a process being improved in a Six Sigma project.

4. Regression Analysis
They move closer to the center line.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
No -- if it is not the same - it can only be worse!

5. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Deming.
QFD
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Variable.

6. How are LQL and AQL determined in an acceptance sampling plan?
Sort - Set in Order - Shine - Standardize - Sustain
Initiated before or at design concept finalization
An assertion or conjecture concerning one or more populations
Through producer/consumer negotiation.

7. What is the center line of an X-bar chart?
A diagram that shows the relationships between activities in a project network.
Lean is waste reduction - Six Sigma is variation reduction.
X-bar-bar
Speed - courtesy - competence - and ease of repair.

8. If you can only collect categorical data - what type of SPC charting can you do?
A time series plot.
Defects Per Million Opportunities
Attribute.
Fitness for use.

9. Why do you need two control charts for variables SPC?
Consumer risk.
Conformance to specifications.
Because the mean and standard deviation are independent of each other.
An assertion or conjecture concerning one or more populations

10. Define product reliability.
Mean time to failure.
The ability of a process to consistently meet customer specifications.
Critical to quality.
No -- if it is not the same - it can only be worse!

11. For what is an x-bar chart used?
To monitor a process when measurement by variables is used.
Workers - machines - materials.
An assertion or conjecture concerning one or more populations
68%

12. Test for constant variance
It looks to minimize the probability of a failure - or to minimize its effects
Reliability - Assurance - Responsiveness - Tangibles - Empathy
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.
Upper control limit.

13. What type of risk is associated with Type 1 Error?
Producer risk.
Different types of defects are listed (used for Pareto chart)
To obtain a certain desirable outcome from the process
Supplier - input - process - output - customer.

14. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Lower skill requirements - faster - less chance for error.
False - because each machine will have different natural tolerances.
Kaoru Ishikawa.
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

15. Define yield.
To do a capability study for a non-centered process.
Sampling for SPC is done real time.
The ratio of outputs to inputs; 1-scrap.
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

16. Does it ever make sense to accept a job when a process is incapable?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Lower control limit.
Shifts - Trends - Repeating patterns - Correlation with known events
The primary operating characteristics of a product.

17. What is the difference between Lean and Six Sigma?
The ratio of outputs to inputs; 1-scrap.
To be a member of a Six Sigma project team.
Lean is waste reduction - Six Sigma is variation reduction.
Prevention and appraisal costs are balanced against internal and external failure.

18. What does SIPOC stand for?
Supplier - input - process - output - customer.
No -- the variation also has to be random and "expected."
Mean time to replacement.
They move closer to the center line.

19. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Conformance to specifications.
Controlling quality at the source.
Brand image.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

20. Failure Mode
The number of standard deviations some value is from the mean.
5%
Is the way in which the failure is manifested.
Initiated before or at design concept finalization

21. PFMEA
Hold all input variables constant except one. Observe the response as you vary the single input.
Before production starts
=sqrt(Σ(x-x-bar)^2)/(n-1))
A tool that shows the physical flows through a space.

22. Based on what principal can we use the normal distribution assumptions for SPC?
Because the mean and standard deviation are independent of each other.
Central Limit Theorem
Variable.
Defects Per Million Opportunities

23. What is the center line of a p-chart?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Prevention - appraisal - internal failure - external failure.
p-bar - the long-run percent defective.

24. Failure effect
Scrap - rework - retest - downtime - yield losses - disposition costs.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Is the consequence of the failure.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

25. What does Crosby say about benchmarking?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
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.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
95%

26. How does Juran define quality?
Sort - Set in Order - Shine - Standardize - Sustain
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
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Fitness for use.

27. If a three-stage process has 90% yields at each stage - what is the overall yield?
Concluding there has not been an effect/change when there has.
Fitness for use.
Stratify a particular defect type according to logical criteria
0.9^3 or 72.9%

28. Define performance quality.
Represents the behavior of a process
The primary operating characteristics of a product.
An assertion or conjecture concerning one or more populations
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

29. Histogram by Hand
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
10 for Hazardous without warning 1 for none
Sampling for SPC is done real time.
Controlling quality at the source.

30. 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).
What the value of the dependent variable is when the independent variable is zero.
A time series plot.

31. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Inventory = throughput x flow time.
=sqrt(Σ(x-x-bar)^2)/(n-1))
5%

32. What is an affinity diagram?
F_alpha - df(tr) - df (error)
Prevention and appraisal costs are balanced against internal and external failure.
A brainstorming tool that shows the connections between ideas.
Mean time to replacement.

33. F value
Define - measure - analyze - design - verify.
Concluding there has been an effect/change when there has not.
F_alpha - df(tr) - df (error)
A tool that shows performance along key dimensions all at once.

34. What is the role of a master black belt?
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:
To mentor/coach (and sometimes train) black belts.
A descending order-sorted bar chart with a cumulative percentage line.
Fewer good units to sell - increased variable cost/unit.

35. Manual Test for Nomality
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
95%
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

36. Taguchi's experimental designs are of this type.
Look for the assignable cause of non-random variation.
Initiated before or at design concept finalization
Fractional factorial designs (orthogonal arrays)
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

37. TWO-DIMENTIONAL SCATTER PLOT
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Workers - machines - materials.
A tool that shows where there is waste in a process.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

38. When yields decrease - what are the two effects on contribution?
To obtain a certain desirable outcome from the process
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Fewer good units to sell - increased variable cost/unit.
Organize ideas into meaningful categories by recognizing their underlying similarity

39. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Fitness for use.
Prevention and appraisal costs are balanced against internal and external failure.
F_alpha - df(tr) - df (error)
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).

40. Defect location check sheets
Workers - machines - materials.
Mean time to replacement.
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
Actual drawings - layouts - maps - etc which show where a defect occurs

41. Uses of regression
Prevention - appraisal - internal failure - external failure.
0.9^3 or 72.9%
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Fewer good units to sell - increased variable cost/unit.

42. Define conformance quality.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Outside.
The degree to which a product meets pre-established standards.
The manager in charge of a process being improved in a Six Sigma project.

43. What is the Baldrige Award?
Walter A. Shewhart
The US national quality award.
Critical to quality.
Causes that lead to a particular effect.

44. Simple Regression Analysis (one factor regression model)
The gap between what management thinks customers want and what customers really want.
= 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
=sqrt((p*(1-p)/n)
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

45. What do you do when a process is out of control?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Mistake-proofing.
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).
Look for the assignable cause of non-random variation.

46. What is the formula for the standard deviation of a proportion?
The primary operating characteristics of a product.
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)
Before production starts

47. The data points on an SPC p-chart of defective percent plot below the mean. Is this good or bad?

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48. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
99.73%
Concluding there has not been an effect/change when there has.
A descending order-sorted bar chart with a cumulative percentage line.
A tool that shows where there is waste in a process.

49. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
100%
Mean time to replacement.
A scatterplot.

50. What size should samples be for attribute SPC?
Brand image.
Define - measure - analyze - improve - control.
Large enough to find two of the attribute - on average.
Shifts - Trends - Repeating patterns - Correlation with known events

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