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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. What is the Baldrige Award?
50%
Is what induces the failure
The US national quality award.
Hold all input variables constant except one. Observe the response as you vary the single input.

2. What size should samples be for attribute SPC?
Large enough to find two of the attribute - on average.
Shifts - Trends - Repeating patterns - Correlation with known events
The degree to which a product meets pre-established standards.
Blame.

3. What are the three main categories of assignable cause?
Central Limit Theorem
Pleasing to the senses.
Studying firms with the best performance in a particular area.
Workers - machines - materials.

4. Daniel Test
Fractional factorial designs (orthogonal arrays)
QFD
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:
The number of standard deviations some value is from the mean.

5. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
Variable.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
X-bar-bar

6. What do you do when a process is out of control?
Define - measure - analyze - design - verify.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Look for the assignable cause of non-random variation.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

7. Explain the difference between technical and functional service quality.
Mean time to replacement.
A descending order-sorted bar chart with a cumulative percentage line.
The gap between what is promised and what is delivered.
Technical quality is the "what" of the service; functional quality is the "how."

8. What is FMEA?
Waste.
Deming.
F_alpha - df(tr) - df (error)
Failure Modes and Effects Analysis

9. What quality guru emphasizes management as a system?
Brand image.
3.4 (assuming 1.5 sigma shift in the mean)
10 if Almost impossible to detect
Deming.

10. In the Service Quality Gap Model - what is Gap 1?
Workers - machines - materials.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
3.4 (assuming 1.5 sigma shift in the mean)
The gap between what management thinks customers want and what customers really want.

11. Define serviceability.
Speed - courtesy - competence - and ease of repair.
Hold all input variables constant except one. Observe the response as you vary the single input.
Linearity - normality - homoscedasticity - independence.
They move closer to the center line.

12. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
Represents the behavior of a process
Linearity - normality - homoscedasticity - independence.
To do a capability study for a non-centered process.

13. What is a spaghetti diagram?
To do a capability study for a non-centered process.
A random variable that summarizes the information from the sample(s).
Technical quality is the "what" of the service; functional quality is the "how."
A tool that shows the physical flows through a space.

14. Uses of regression - Control
Hold all input variables constant except one. Observe the response as you vary the single input.
To obtain a certain desirable outcome from the process
A diagram that shows the relationships between activities in a project network.
The cycle time required to meet demand.

15. What does SIPOC stand for?
The House of Quality.
Supplier - input - process - output - customer.
Linearity - normality - homoscedasticity - independence.
Failure Modes and Effects Analysis

16. What does DMAIC stand for?
Large enough to find two of the attribute - on average.
Upper control limit.
Define - measure - analyze - improve - control.
Attribute.

17. For what is an x-bar chart used?
To monitor a process when measurement by variables is used.
Deming.
Is what induces the failure
Organize ideas into meaningful categories by recognizing their underlying similarity

18. 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
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Taguchi
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:

19. Definition of Interaction
A time series plot.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The ratio of outputs to inputs; 1-scrap.

20. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Is the way in which the failure is manifested.
Assigns scores to weighted criteria for each project under consideration.
5%

21. Pareto Analysis
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Organize ideas into meaningful categories by recognizing their underlying similarity
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
To obtain a certain desirable outcome from the process

22. What is an affinity diagram?
Shifts - Trends - Repeating patterns - Correlation with known events
Prevention and appraisal costs are balanced against internal and external failure.
A brainstorming tool that shows the connections between ideas.
Before production starts

23. What are two other names for an Ishikawa diagram?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
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
Fishbone - cause-and-effect diagram.
Waste.

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

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25. FMEA
Because the mean and standard deviation are independent of each other.
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
Taguchi
To manage the Six Sigma project.

26. List two components of internal failure.
Attribute
Failure Modes and Effects Analysis
Scrap - rework - retest - downtime - yield losses - disposition costs.
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).

27. Stratified defect check sheets
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
The gap between what customers expect and the service they receive.
Stratify a particular defect type according to logical criteria
=sqrt(Σ(x-x-bar)^2)/(n-1))

28. Detection Criteria Ranking
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
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
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
10 if Almost impossible to detect

29. Residual
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Variable.
Technical quality is the "what" of the service; functional quality is the "how."
A tool that shows performance along key dimensions all at once.

30. List two components of prevention cost.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Walter A. Shewhart
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

31. What is CTQ?
Critical to quality.
The primary operating characteristics of a product.
Define - measure - analyze - design - verify.
The ratio of outputs to inputs; 1-scrap.

32. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Pleasing to the senses.
To obtain a certain desirable outcome from the process
The gap between specifications and how service is performed.
Prevention and appraisal costs are balanced against internal and external failure.

33. Who developed the fishbone diagram?
Kaoru Ishikawa.
The gap between what customers expect and the service they receive.
Lower skill requirements - faster - less chance for error.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

34. Define benchmarking.
Studying firms with the best performance in a particular area.
Workers - machines - materials.
Initiated before or at design concept finalization
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

35. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Conformance to specifications.
= 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
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).
X-bar-bar

36. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Fractional factorial designs (orthogonal arrays)
Controlling quality at the source.
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).
Variable.

37. Test for Independence
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Linearity - normality - homoscedasticity - 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
Speed - courtesy - competence - and ease of repair.

38. Complete this quality phrase: 'Fix the process - not the _____.'
Blame.
Assigns scores to weighted criteria for each project under consideration.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

39. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Inventory = throughput x flow time.
= 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
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
95%

40. How does Juran define quality?
Fitness for use.
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.
Mistake-proofing.
To obtain a certain desirable outcome from the process

41. When is Cpk used?
A diagram that shows the relationships between activities in a project network.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
To do a capability study for a non-centered process.

42. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
An assertion or conjecture concerning one or more populations
99.73%
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
Attribute

43. Test for constant variance
To monitor a process when measurement by variables is used.
The ability of a process to consistently meet customer specifications.
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.
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

44. What does Crosby say about benchmarking?
68%
The cycle time required to meet demand.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Attribute.

45. What is Jidoka?
It's good -- but it's still out of control!
Controlling quality at the source.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Attribute.

46. In the Service Quality Gap Model - what is Gap 3?
Walter A. Shewhart
Stratify a particular defect type according to logical criteria
The gap between specifications and how service is performed.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

47. What is a Gantt chart?
Shows the temporal flow of activities in a project network.
Critical to quality.
Failure Modes and Effects Analysis
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

48. What are the four categories of costs in Juran's framework?
Prevention - appraisal - internal failure - external failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Large enough to find two of the attribute - on average.
50%

49. TWO-DIMENTIONAL SCATTER PLOT
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
False - because each machine will have different natural tolerances.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Central Limit Theorem

50. With Six Sigma capability - how many defects per million opportunities would you see?
Lean is waste reduction - Six Sigma is variation reduction.
3.4 (assuming 1.5 sigma shift in the mean)
Upper control limit.
=sqrt((p*(1-p)/n)

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