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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. Define durability.
Actual drawings - layouts - maps - etc which show where a defect occurs
Mean time to replacement.
Brand image.
The target number of standard deviations from the mean for specifications.

2. What is written on the "spines" of a fishbone diagram?
A tool that shows where there is waste in a process.
Causes that lead to a particular effect.
Before production starts
A diagram that shows the relationships between activities in a project network.

3. What does the abbreviation LCL stand for?
Mean time to replacement.
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
Lower control limit.
X-bar-bar

4. Who first studied randomness in industrial processes
Walter A. Shewhart
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Organize ideas into meaningful categories by recognizing their underlying similarity
Critical to quality.

5. Process check sheets
Someone who is consistently against virtually everything.
Prevention - appraisal - internal failure - external failure.
The primary operating characteristics of a product.
Used to create frequency distribution tally sheets

6. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
To obtain a certain desirable outcome from the process
68%
Attribute

7. Simple Regression Analysis (one factor regression model)
= 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 primary operating characteristics of a product.
It looks to minimize the probability of a failure - or to minimize its effects
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

8. What are the four regression assumptions?
The gap between what management thinks customers want and what customers really want.
Linearity - normality - homoscedasticity - independence.
A brainstorming tool that shows the connections between ideas.
The number of standard deviations some value is from the mean.

9. What is a dashboard?
Mistake-proofing.
The Japanese national quality award.
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
A tool that shows performance along key dimensions all at once.

10. If a three-stage process has 90% yields at each stage - what is the overall yield?
To monitor a process when measurement by variables is used.
0.9^3 or 72.9%
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

11. 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?
Controlling quality at the source.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
False - because each machine will have different natural tolerances.
Pleasing to the senses.

12. What is the difference between Lean and Six Sigma?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Critical to quality.
Lean is waste reduction - Six Sigma is variation reduction.
Prevention - appraisal - internal failure - external failure.

13. Definition of Interaction
Large enough to find two of the attribute - on average.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Fishbone - cause-and-effect diagram.
Not necessarily.

14. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
95%
Can't tell without a Range chart.
To monitor a process when measurement by attribute is used.

15. If you have calculated a Cpk - should you also calculate a Cp?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Failure Modes and Effects Analysis
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
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

16. What is a Gantt chart?
=sqrt(Σ(x-x-bar)^2)/(n-1))
To obtain a certain desirable outcome from the process
Because the mean and standard deviation are independent of each other.
Shows the temporal flow of activities in a project network.

17. For what is a p-chart used?
Linearity - normality - homoscedasticity - independence.
To monitor a process when measurement by attribute is used.
Consumer risk.
Attribute.

18. Regression
The gap between what customers expect and the service they receive.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Represents the behavior of a process
Central Limit Theorem

19. What is a run chart?
=sqrt((p*(1-p)/n)
=sqrt(Σ(x-x-bar)^2)/(n-1))
A time series plot.
The number of standard deviations some value is from the mean.

20. When yields decrease - what are the two effects on contribution?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Before production starts
Fewer good units to sell - increased variable cost/unit.
Can't tell without a Range chart.

21. What type of risk is associated with Type 1 Error?
Sampling for SPC is done real time.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Producer risk.
The Japanese national quality award.

22. What is the 5S model?
A descending order-sorted bar chart with a cumulative percentage line.
Sort - Set in Order - Shine - Standardize - Sustain
Define - measure - analyze - improve - control.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

23. Name the structure associated with Quality Function Deployment.
The House of Quality.
To monitor a process when measurement by attribute is used.
Organize ideas into meaningful categories by recognizing their underlying similarity
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

24. What graphical tool is used to show the relationship between two numerical variables?
Sort - Set in Order - Shine - Standardize - Sustain
A scatterplot.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
An assertion or conjecture concerning one or more populations

25. DFMEA
A scatterplot.
Initiated before or at design concept finalization
No -- only if the process is also capable.
X-bar-bar

26. In a regression - what does the coefficient of the intercept tell you
Organize ideas into meaningful categories by recognizing their underlying similarity
What the value of the dependent variable is when the independent variable is zero.
Conformance to specifications.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

27. 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).
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
A tool that shows the physical flows through a space.

28. What is the center line of an X-bar chart?
Consumer risk.
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
Define - measure - analyze - improve - control.
X-bar-bar

29. List two components of prevention cost.
F_alpha - df(tr) - df (error)
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Is the way in which the failure is manifested.
Consumer risk.

30. What does SIPOC stand for?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
They move closer to the center line.
Supplier - input - process - output - customer.
3.4 (assuming 1.5 sigma shift in the mean)

31. Failure Mode
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Is the way in which the failure is manifested.
Large enough to find two of the attribute - on average.
The secondary characteristics of a product; "bells and whistles."

32. Which quality guru developed the concept of loss to society?
Brand image.
10 if Almost impossible to detect
Taguchi
3.4 (assuming 1.5 sigma shift in the mean)

33. In the Service Quality Gap Model - what is Gap 1?
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 management thinks customers want and what customers really want.
Different types of defects are listed (used for Pareto chart)
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).

34. Define serviceability.
Speed - courtesy - competence - and ease of repair.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Different types of defects are listed (used for Pareto chart)
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

35. Non-random patterns (Run Charts)
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
Shifts - Trends - Repeating patterns - Correlation with known events
Method developed by Ishikawa to graphically display the causes of any given problem
The gap between what is promised and what is delivered.

36. Defect check sheets
Different types of defects are listed (used for Pareto chart)
Outside.
To be a member of a Six Sigma project team.
Sampling for SPC is done real time.

37. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
No -- the variation also has to be random and "expected."
Producer risk.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Inventory = throughput x flow time.

38. Risk Priority Number RPN
Define - measure - analyze - design - verify.
= 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.
The primary operating characteristics of a product.

39. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
99.73%
The number of standard deviations some value is from the mean.
Financial - customer - internal process - innovation and learning.
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

40. If a Cp shows that a process is not capable - should you calculate Cpk?
10 if Almost impossible to detect
Can't tell without a Range chart.
Different types of defects are listed (used for Pareto chart)
No -- if it is not the same - it can only be worse!

41. Explain the difference between technical and functional service quality.
Technical quality is the "what" of the service; functional quality is the "how."
Fractional factorial designs (orthogonal arrays)
A time series plot.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

42. FMEA
Define - measure - analyze - design - verify.
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
They move closer to the center line.
The degree to which a product meets pre-established standards.

43. List two components of internal failure.
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 descending order-sorted bar chart with a cumulative percentage line.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Scrap - rework - retest - downtime - yield losses - disposition costs.

44. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Lean (or JIT).
Fitness for use.
The secondary characteristics of a product; "bells and whistles."
Conformance to specifications.

45. What is a histogram?
To obtain a certain desirable outcome from the process
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Scrap - rework - retest - downtime - yield losses - disposition costs.
= yij - y(bar)i --> value minus sum of that treatment (of row)

46. What are the three main categories of assignable cause?
Workers - machines - materials.
Walter A. Shewhart
F_alpha - df(tr) - df (error)
99.73%

47. In the Service Quality Gap Model - what is Gap 2?
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 brainstorming tool that shows the connections between ideas.
The gap between what management thinks customers want and the process specifications.
Lower skill requirements - faster - less chance for error.

48. In a regression - what does the p value of F tell you?
To monitor a process when measurement by attribute is used.
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).
The secondary characteristics of a product; "bells and whistles."
Causes that lead to a particular effect.

49. Define benchmarking.
Outside.
Assigns scores to weighted criteria for each project under consideration.
Studying firms with the best performance in a particular area.
Define - measure - analyze - improve - control.

50. What is Value Stream Mapping?
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
A tool that shows where there is waste in a process.
A tool that shows the physical flows through a space.
A scatterplot.

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