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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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1. What are the three main categories of assignable cause?
Is what induces the failure
Workers - machines - materials.
Attribute
Hold all input variables constant except one. Observe the response as you vary the single input.

2. What is the formula for standard deviation?
F_alpha - df(tr) - df (error)
=sqrt(Σ(x-x-bar)^2)/(n-1))
The target number of standard deviations from the mean for specifications.
No -- if it is not the same - it can only be worse!

3. DFMEA
Supplier - input - process - output - customer.
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!
Initiated before or at design concept finalization

4. List Garvin's eight dimensions of product quality.
To mentor/coach (and sometimes train) black belts.
Upper control limit.
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.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

5. Disadvantages of DOE

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6. What is a network diagram?
Upper control limit.
A diagram that shows the relationships between activities in a project network.
The House of Quality.
68%

7. Define aesthetic quality.
Actual drawings - layouts - maps - etc which show where a defect occurs
= 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
Pleasing to the senses.
Attribute.

8. Affinity Diagrams
Organize ideas into meaningful categories by recognizing their underlying similarity
Lower skill requirements - faster - less chance for error.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Prevention and appraisal costs are balanced against internal and external failure.

9. What is a Gage R&R?
99.73%
Waste.
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).
=sqrt(Σ(x-x-bar)^2)/(n-1))

10. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Is the consequence of the failure.
Failure Modes and Effects Analysis
The gap between what management thinks customers want and what customers really want.
Sampling for SPC is done real time.

11. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Can't tell without a Range chart.
Concluding there has not been an effect/change when there has.
Kaoru Ishikawa.
Prevention and appraisal costs are balanced against internal and external failure.

12. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Prevention - appraisal - internal failure - external failure.
Conformance to specifications.
Attribute
The House of Quality.

13. In the Service Quality Gap Model - what is Gap 2?
The gap between what management thinks customers want and the process specifications.
Variable.
The target number of standard deviations from the mean for specifications.
Fewer good units to sell - increased variable cost/unit.

14. In a regression - what does the standard error of the estimate tell you?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
To manage the Six Sigma project.
Controlling quality at the source.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

15. For what is an x-bar chart used?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
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
To monitor a process when measurement by variables is used.

16. 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?
Fractional factorial designs (orthogonal arrays)
Hold all input variables constant except one. Observe the response as you vary the single input.
p-bar - the long-run percent defective.
False - because each machine will have different natural tolerances.

17. How does Juran define quality?
99.73%
The secondary characteristics of a product; "bells and whistles."
Fitness for use.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

18. Manual Test for Nomality
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Stratify a particular defect type according to logical criteria
The degree to which a product meets pre-established standards.
Represents the behavior of a process

19. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Lean (or JIT).
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Attribute.
What the value of the dependent variable is when the independent variable is zero.

20. With Six Sigma capability - how many defects per million opportunities would you see?
Lean (or JIT).
Controlling quality at the source.
3.4 (assuming 1.5 sigma shift in the mean)
Critical to quality.

21. Failure effect
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Producer risk.
Is the consequence of the failure.
Used to create frequency distribution tally sheets

22. What is the difference between Lean and Six Sigma?
Prevention and appraisal costs are balanced against internal and external failure.
Lean is waste reduction - Six Sigma is variation reduction.
What the value of the dependent variable is when the independent variable is zero.
Can't tell without a Range chart.

23. What size should samples be for attribute SPC?
False - because each machine will have different natural tolerances.
Look for the assignable cause of non-random variation.
Large enough to find two of the attribute - on average.
Failure Modes and Effects Analysis

24. What is CTQ?
What the value of the dependent variable is when the independent variable is zero.
Define - measure - analyze - improve - control.
They move closer to the center line.
Critical to quality.

25. Define conformance quality.
The degree to which a product meets pre-established standards.
To manage the Six Sigma project.
A time series plot.
An assertion or conjecture concerning one or more populations

26. 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).
An assertion or conjecture concerning one or more populations
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Initiated before or at design concept finalization

27. Explain the difference between technical and functional service quality.
100%
Large enough to find two of the attribute - on average.
Technical quality is the "what" of the service; functional quality is the "how."
The degree to which a product meets pre-established standards.

28. Uses of regression - Control
Brand image.
Mean time to failure.
To obtain a certain desirable outcome from the process
Linearity - normality - homoscedasticity - independence.

29. What is DPMO?
Initiated before or at design concept finalization
Defects Per Million Opportunities
Studying firms with the best performance in a particular area.
Large enough to find two of the attribute - on average.

30. What does SIPOC stand for?
Supplier - input - process - output - customer.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Defects Per Million Opportunities

31. 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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32. Taguchi's experimental designs are of this type.
Blame.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Fractional factorial designs (orthogonal arrays)
Large enough to find two of the attribute - on average.

33. Who developed the fishbone diagram?
Kaoru Ishikawa.
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!"
Someone who is consistently against virtually everything.

34. Statistical Hypothesis
QFD
An assertion or conjecture concerning one or more populations
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Scrap - rework - retest - downtime - yield losses - disposition costs.

35. In a Z table - what is Z?
Attribute.
Fractional factorial designs (orthogonal arrays)
The number of standard deviations some value is from the mean.
Shifts - Trends - Repeating patterns - Correlation with known events

36. When yields decrease - what are the two effects on contribution?
Waste.
Lower skill requirements - faster - less chance for error.
Fewer good units to sell - increased variable cost/unit.
Kaoru Ishikawa.

37. In the Service Quality Gap Model - what is Gap 1?
Scrap - rework - retest - downtime - yield losses - disposition costs.
The gap between what management thinks customers want and what customers really want.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Can't tell without a Range chart.

38. If a Cp shows that a process is not capable - should you calculate Cpk?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
68%
No -- if it is not the same - it can only be worse!
Method developed by Ishikawa to graphically display the causes of any given problem

39. What is Kaizen?
Method developed by Ishikawa to graphically display the causes of any given problem
Not necessarily.
They move closer to the center line.
Rapid improvement process.

40. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Sort - Set in Order - Shine - Standardize - Sustain
Taguchi
Concluding there has not been an effect/change when there has.
68%

41. What are the four perspectives of the Balanced Scorecard?
Shows the temporal flow of activities in a project network.
Financial - customer - internal process - innovation and learning.
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).
Critical to quality.

42. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Waste.
Not necessarily.

43. Daniel Test
= 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
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:
Lean (or JIT).
Attribute.

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

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45. What does DMAIC stand for?
Define - measure - analyze - improve - control.
Fewer good units to sell - increased variable cost/unit.
It looks to minimize the probability of a failure - or to minimize its effects
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

46. TWO-DIMENTIONAL SCATTER PLOT
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Different types of defects are listed (used for Pareto chart)
95%
Shows the temporal flow of activities in a project network.

47. F value
F_alpha - df(tr) - df (error)
To monitor a process when measurement by attribute is used.
Assigns scores to weighted criteria for each project under consideration.
Fishbone - cause-and-effect diagram.

48. In a regression - what does the p value of F tell you?
A tool that shows where there is waste in a process.
F_alpha - df(tr) - df (error)
To obtain a certain desirable outcome from the process
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).

49. ANOVA

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50. What is poka yoke?
0.9^3 or 72.9%
Is what induces the failure
Mistake-proofing.
Concluding there has not been an effect/change when there has.

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