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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. Definition of Interaction
Critical to quality.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Producer risk.
The Japanese national quality award.

2. Failure Mode
A tool that shows performance along key dimensions all at once.
10 if Almost impossible to detect
The Japanese national quality award.
Is the way in which the failure is manifested.

3. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Outside.
Is the way in which the failure is manifested.
Method developed by Ishikawa to graphically display the causes of any given problem

4. In a regression - what does R-square tell you?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Outside.
10 if Almost impossible to detect
= 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

5. What is a network diagram?
They move closer to the center line.
The gap between what is promised and what is delivered.
To monitor a process when measurement by variables is used.
A diagram that shows the relationships between activities in a project network.

6. In the Service Quality Gap Model - what is Gap 4?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The gap between what is promised and what is delivered.
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).
0.9^3 or 72.9%

7. List two components of external failure.
Attribute.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
10 if Almost impossible to detect
Rapid improvement process.

8. In a Z table - what is Z?
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
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Fishbone - cause-and-effect diagram.
The number of standard deviations some value is from the mean.

9. What are the 5 Ss?
The number of standard deviations some value is from the mean.
No -- if it is not the same - it can only be worse!
Sort - Set in Order - Shine - Standardize - Sustain
Before production starts

10. If a three-stage process has 90% yields at each stage - what is the overall yield?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Used to create frequency distribution tally sheets
0.9^3 or 72.9%
A brainstorming tool that shows the connections between ideas.

11. 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
Attribute
Stratify a particular defect type according to logical criteria
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

12. What does the abbreviation UCL stand for?
Upper control limit.
Not necessarily.
Conformance to specifications.
Mean time to replacement.

13. List Garvin's eight dimensions of product quality.
What the value of the dependent variable is when the independent variable is zero.
QFD
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
0.9^3 or 72.9%

14. What does the abbreviation LCL stand for?
They move closer to the center line.
Define - measure - analyze - improve - control.
Causes that lead to a particular effect.
Lower control limit.

15. Name the structure associated with Quality Function Deployment.
A diagram that shows the relationships between activities in a project network.
The House of Quality.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
No -- if it is not the same - it can only be worse!

16. What is poka yoke?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Lean is waste reduction - Six Sigma is variation reduction.
Mistake-proofing.
Through producer/consumer negotiation.

17. Define yield.
Look for the assignable cause of non-random variation.
Fractional factorial designs (orthogonal arrays)
Causes that lead to a particular effect.
The ratio of outputs to inputs; 1-scrap.

18. What is muda
50%
Deming.
Lean (or JIT).
Waste.

19. What is FMEA?
Stratify a particular defect type according to logical criteria
A random variable that summarizes the information from the sample(s).
A scatterplot.
Failure Modes and Effects Analysis

20. 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
No -- only if the process is also capable.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
A tool that shows performance along key dimensions all at once.

21. Simple Regression Analysis (one factor regression model)
50%
Scrap - rework - retest - downtime - yield losses - disposition costs.
Defects Per Million Opportunities
= 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

22. What is the center line of an X-bar chart?
=sqrt((p*(1-p)/n)
X-bar-bar
Lean is waste reduction - Six Sigma is variation reduction.
It looks to minimize the probability of a failure - or to minimize its effects

23. Uses of regression
The gap between what customers expect and the service they receive.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Speed - courtesy - competence - and ease of repair.
Fewer good units to sell - increased variable cost/unit.

24. What quality tool formally incorporates the voice of the customer?
QFD
99.73%
Stratify a particular defect type according to logical criteria
Shows the temporal flow of activities in a project network.

25. What is an affinity diagram?
Mean time to replacement.
A brainstorming tool that shows the connections between ideas.
What the value of the dependent variable is when the independent variable is zero.
Define - measure - analyze - design - verify.

26. What is Type II Error?
To do a capability study for a non-centered process.
Scrap - rework - retest - downtime - yield losses - disposition costs.
To monitor a process when measurement by variables is used.
Concluding there has not been an effect/change when there has.

27. List two components of prevention cost.
Shifts - Trends - Repeating patterns - Correlation with known events
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
The gap between what is promised and what is delivered.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

28. Which type of SPC measurement is more precise - variable or attribute?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
A random variable that summarizes the information from the sample(s).
Variable.
Attribute

29. What are the four categories of costs in Juran's framework?
Fishbone - cause-and-effect diagram.
The gap between specifications and how service is performed.
Prevention - appraisal - internal failure - external failure.
Causes that lead to a particular effect.

30. What type of risk is associated with Type II Error?
To obtain a certain desirable outcome from the process
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
Lean is waste reduction - Six Sigma is variation reduction.
Consumer risk.

31. Manual Test for Nomality
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:
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
No -- the variation also has to be random and "expected."
A scatterplot.

32. Process check sheets
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Mistake-proofing.
Used to create frequency distribution tally sheets
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

33. FMEA
It looks to minimize the probability of a failure - or to minimize its effects
Before production starts
Pleasing to the senses.
No -- if it is not the same - it can only be worse!

34. Risk Priority Number RPN
Fitness for use.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
=sqrt((p*(1-p)/n)
X-bar-bar

35. Process occurance ranking
50%
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
10 if Almost impossible to detect
Fewer good units to sell - increased variable cost/unit.

36. Why do you need two control charts for variables SPC?
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
Because the mean and standard deviation are independent of each other.
They move closer to the center line.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

37. Define aesthetic quality.
Prevention - appraisal - internal failure - external failure.
The gap between what is promised and what is delivered.
Pleasing to the senses.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

38. Effect ranking (Severity of the Defect)
Sampling for SPC is done real time.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
10 for Hazardous without warning 1 for none
50%

39. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
Upper control limit.
100%
A tool that shows the physical flows through a space.
Different types of defects are listed (used for Pareto chart)

40. What is process capability?
The ability of a process to consistently meet customer specifications.
95%
Prevention - appraisal - internal failure - external failure.
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:

41. DFMEA
Because the mean and standard deviation are independent of each other.
Fitness for use.
Initiated before or at design concept finalization
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

42. What is the 5S model?
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
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The gap between what management thinks customers want and the process specifications.

43. Presence of interaction effect
Critical to quality.
Define - measure - analyze - improve - control.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
A time series plot.

44. If you can only collect categorical data - what type of SPC charting can you do?
Workers - machines - materials.
Defects Per Million Opportunities
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Attribute.

45. When yields decrease - what are the two effects on contribution?
Fewer good units to sell - increased variable cost/unit.
A descending order-sorted bar chart with a cumulative percentage 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

46. 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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47. DOE
99.73%
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
To do a capability study for a non-centered process.

48. 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."
Is the consequence of the failure.
Mean time to replacement.
QFD

49. Complete this quality phrase: 'Fix the process - not the _____.'
A descending order-sorted bar chart with a cumulative percentage line.
Linearity - normality - homoscedasticity - independence.
Blame.
Hold all input variables constant except one. Observe the response as you vary the single input.

50. What does DMAIC stand for?
= 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
A tool that shows the physical flows through a space.
Define - measure - analyze - improve - control.
Lower skill requirements - faster - less chance for error.

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