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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 is written on the "spines" of a fishbone diagram?
The gap between what management thinks customers want and what customers really want.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Causes that lead to a particular effect.
A tool that shows performance along key dimensions all at once.

2. Complete this quality phrase: 'Fix the process - not the _____.'
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Blame.
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
5%

3. What happens to control limits on an SPC chart when sample size is increased?
Lower control limit.
They move closer to the center line.
Consumer risk.
Someone who is consistently against virtually everything.

4. In the Service Quality Gap Model - what is Gap 5?
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 number of standard deviations some value is from the mean.
Waste.
The gap between what customers expect and the service they receive.

5. If you can only collect categorical data - what type of SPC charting can you do?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Attribute.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

6. Who developed the fishbone diagram?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Upper control limit.
Kaoru Ishikawa.
Is the way in which the failure is manifested.

7. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
They move closer to the center line.
Outside.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Define - measure - analyze - improve - control.

8. Failure Mode
Sort - Set in Order - Shine - Standardize - Sustain
The gap between specifications and how service is performed.
Is the way in which the failure is manifested.
Fishbone - cause-and-effect diagram.

9. Histogram by Hand
Kaoru Ishikawa.
The ability of a process to consistently meet customer specifications.
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
Variable.

10. Detection Criteria Ranking
A scatterplot.
10 if Almost impossible to detect
Method developed by Ishikawa to graphically display the causes of any given problem
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:

11. What is the 5S model?
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.
To monitor a process when measurement by attribute is used.
Initiated before or at design concept finalization

12. Pareto Analysis
Shifts - Trends - Repeating patterns - Correlation with known events
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
The gap between what customers expect and the service they receive.

13. What does a project prioritization matrix do?
Assigns scores to weighted criteria for each project under consideration.
Different types of defects are listed (used for Pareto chart)
The target number of standard deviations from the mean for specifications.
The gap between what customers expect and the service they receive.

14. List two appraisal costs.
Not necessarily.
Concluding there has been an effect/change when there has not.
Outside.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

15. If a Cp shows that a process is not capable - should you calculate Cpk?
To be a member of a Six Sigma project team.
Critical to quality.
No -- if it is not the same - it can only be worse!
Workers - machines - materials.

16. What does Crosby say about benchmarking?
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
No -- if it is not the same - it can only be worse!
Outside.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

17. 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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18. What is FMEA?
Rapid improvement process.
Failure Modes and Effects Analysis
To obtain a certain desirable outcome from the process
Brand image.

19. Define yield.
Organize ideas into meaningful categories by recognizing their underlying similarity
Prevention - appraisal - internal failure - external failure.
Controlling quality at the source.
The ratio of outputs to inputs; 1-scrap.

20. Non-random patterns (Run Charts)
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Concluding there has been an effect/change when there has not.
Shifts - Trends - Repeating patterns - Correlation with known events
To be a member of a Six Sigma project team.

21. What is the role of a master black belt?
False - because each machine will have different natural tolerances.
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.
Deming.

22. 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
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Is the consequence of the failure.

23. What do you do when a process is out of control?
A random variable that summarizes the information from the sample(s).
Look for the assignable cause of non-random variation.
68%
To do a capability study for a non-centered process.

24. The Test Statistic (TS)
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
A random variable that summarizes the information from the sample(s).
A brainstorming tool that shows the connections between ideas.
Fractional factorial designs (orthogonal arrays)

25. List Garvin's eight dimensions of product quality.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
50%

26. Which quality guru developed the concept of loss to society?
QFD
Because the mean and standard deviation are independent of each other.
Workers - machines - materials.
Taguchi

27. Stratified defect check sheets
No -- the variation also has to be random and "expected."
The cycle time required to meet demand.
Stratify a particular defect type according to logical criteria
Speed - courtesy - competence - and ease of repair.

28. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
A random variable that summarizes the information from the sample(s).
Blame.
The cycle time required to meet demand.

29. Failure cause
Is what induces the failure
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Stratify a particular defect type according to logical criteria
Prevention and appraisal costs are balanced against internal and external failure.

30. What is CTQ?
False - because each machine will have different natural tolerances.
68%
Not necessarily.
Critical to quality.

31. What is a Pareto chart?
It's good -- but it's still out of control!
A tool that shows the physical flows through a space.
Fishbone - cause-and-effect diagram.
A descending order-sorted bar chart with a cumulative percentage line.

32. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
To mentor/coach (and sometimes train) black belts.
The cycle time required to meet demand.
An assertion or conjecture concerning one or more populations

33. How does Juran define quality?
To manage the Six Sigma project.
Fitness for use.
Workers - machines - materials.
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. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Mistake-proofing.
Initiated before or at design concept finalization
The number of standard deviations some value is from the mean.
99.73%

35. PFMEA
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)
Before production starts
Fewer good units to sell - increased variable cost/unit.

36. What is the Baldrige Award?
Upper control limit.
The US national quality award.
Method developed by Ishikawa to graphically display the causes of any given problem
Because the mean and standard deviation are independent of each other.

37. FMEA
To monitor a process when measurement by variables is used.
Scrap - rework - retest - downtime - yield losses - disposition costs.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
It looks to minimize the probability of a failure - or to minimize its effects

38. What does the abbreviation LCL stand for?
The Japanese national quality award.
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
A random variable that summarizes the information from the sample(s).
Lower control limit.

39. With Six Sigma capability - how many defects per million opportunities would you see?
3.4 (assuming 1.5 sigma shift in the mean)
The cycle time required to meet demand.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Not necessarily.

40. Define perceived quality (Garvin's framework).
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.
Fewer good units to sell - increased variable cost/unit.
Brand image.
Fractional factorial designs (orthogonal arrays)

41. What is Jidoka?
Because the mean and standard deviation are independent of each other.
Controlling quality at the source.
It's good -- but it's still out of control!
A diagram that shows the relationships between activities in a project network.

42. Name the structure associated with Quality Function Deployment.
The cycle time required to meet demand.
68%
The House of Quality.
No -- the variation also has to be random and "expected."

43. FMEA
A tool that shows the physical flows through a space.
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
What the value of the dependent variable is when the independent variable is zero.
Method developed by Ishikawa to graphically display the causes of any given problem

44. What percentage of a normal distribution lies above the mean?
p-bar - the long-run percent defective.
Mean time to replacement.
50%
95%

45. 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."
Shows the temporal flow of activities in a project network.
Not necessarily.
Linearity - normality - homoscedasticity - independence.

46. What is Kaizen?
A tool that shows performance along key dimensions all at once.
Actual drawings - layouts - maps - etc which show where a defect occurs
Rapid improvement process.
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

47. What is DPMO?
To mentor/coach (and sometimes train) black belts.
Mistake-proofing.
Can't tell without a Range chart.
Defects Per Million Opportunities

48. What graphical tool is used to show the relationship between two numerical variables?
The gap between specifications and how service is performed.
Through producer/consumer negotiation.
A scatterplot.
Shifts - Trends - Repeating patterns - Correlation with known events

49. One factor at a time (OFAT)
3.4 (assuming 1.5 sigma shift in the mean)
Hold all input variables constant except one. Observe the response as you vary the single input.
A tool that shows where there is waste in a process.
p-bar - the long-run percent defective.

50. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The degree to which a product meets pre-established standards.
Is the way in which the failure is manifested.
Failure Modes and Effects Analysis

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