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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. Manual Test for Nomality
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
An assertion or conjecture concerning one or more populations
Consumer risk.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

2. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Prevention - appraisal - internal failure - external failure.
Lean (or JIT).
Blame.
Mean time to failure.

3. What are the three main categories of assignable cause?
Before production starts
Workers - machines - materials.
To monitor a process when measurement by attribute is used.
Consumer risk.

4. One factor at a time (OFAT)
Observed variation in response is caused by the input
Mean time to replacement.
Prevention - appraisal - internal failure - external failure.
99.73%

5. 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?
False - because each machine will have different natural tolerances.
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
Concluding there has been an effect/change when there has not.
Attribute.

6. 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).
The ability of a process to consistently meet customer specifications.
A tool that shows performance along key dimensions all at once.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

7. What type of risk is associated with Type II Error?
0.9^3 or 72.9%
Inventory = throughput x flow time.
To mentor/coach (and sometimes train) black belts.
Consumer risk.

8. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Fewer good units to sell - increased variable cost/unit.
Conformance to specifications.
Outside.
Inventory = throughput x flow time.

9. What is Jidoka?
Consumer risk.
Lower skill requirements - faster - less chance for error.
The secondary characteristics of a product; "bells and whistles."
Controlling quality at the source.

10. Process occurance ranking
No -- only if the process is also capable.
A random variable that summarizes the information from the sample(s).
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Mean time to failure.

11. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Sampling for SPC is done real time.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
To be a member of a Six Sigma project team.

12. PFMEA
To mentor/coach (and sometimes train) black belts.
Before production starts
Fishbone - cause-and-effect diagram.
Brand image.

13. Define yield.
The ratio of outputs to inputs; 1-scrap.
The US national quality award.
50%
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:

14. What does the abbreviation LCL stand for?
It's good -- but it's still out of control!
Lower skill requirements - faster - less chance for error.
Lower control limit.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

15. DOE
The target number of standard deviations from the mean for specifications.
Lower control limit.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Outside.

16. Affinity Diagrams
Organize ideas into meaningful categories by recognizing their underlying similarity
X-bar-bar
Mean time to failure.
No -- if it is not the same - it can only be worse!

17. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
X-bar-bar
Because the mean and standard deviation are independent of each other.
Lower skill requirements - faster - less chance for error.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

18. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
Observed variation in response is caused by the input
99.73%
Define - measure - analyze - improve - control.

19. Who is a process owner?
QFD
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Used to create frequency distribution tally sheets
The manager in charge of a process being improved in a Six Sigma project.

20. What is a run chart?
Because the mean and standard deviation are independent of each other.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
A time series plot.
What the value of the dependent variable is when the independent variable is zero.

21. What is DMADV?
Is what induces the failure
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
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Define - measure - analyze - design - verify.

22. What is Type II Error?
Is the way in which the failure is manifested.
Concluding there has not been an effect/change when there has.
Supplier - input - process - output - customer.
Failure Modes and Effects Analysis

23. With Six Sigma capability - how many defects per million opportunities would you see?
Critical to quality.
3.4 (assuming 1.5 sigma shift in the mean)
Taguchi
Variable.

24. DFMEA
Initiated before or at design concept finalization
Stratify a particular defect type according to logical criteria
An assertion or conjecture concerning one or more populations
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

25. Your production process meets customer specifications. Is your process in control?
Represents the behavior of a process
Not necessarily.
Defects Per Million Opportunities
Consumer risk.

26. If a Cp shows that a process is not capable - should you calculate Cpk?
No -- if it is not the same - it can only be worse!
0.9^3 or 72.9%
Concluding there has been an effect/change when there has not.
Define - measure - analyze - improve - control.

27. In the Service Quality Gap Model - what is Gap 5?
No -- if it is not the same - it can only be worse!
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
A random variable that summarizes the information from the sample(s).
The gap between what customers expect and the service they receive.

28. What size should samples be for attribute SPC?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Organize ideas into meaningful categories by recognizing their underlying similarity
Workers - machines - materials.
Large enough to find two of the attribute - on average.

29. What is process capability?
Rapid improvement process.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
The ability of a process to consistently meet customer specifications.
Large enough to find two of the attribute - on average.

30. Test for constant variance
The gap between what management thinks customers want and the process 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
To obtain a certain desirable outcome from the process
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.

31. FMEA
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.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
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

32. Process check sheets
To be a member of a Six Sigma project team.
Used to create frequency distribution tally sheets
Critical to quality.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

33. Define durability.
Mean time to replacement.
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
Attribute.
Defects Per Million Opportunities

34. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Variable.
Rapid improvement process.
The degree to which a product meets pre-established standards.
Critical to quality.

35. What does a project prioritization matrix do?
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).
QFD
Assigns scores to weighted criteria for each project under consideration.
No -- only if the process is also capable.

36. What is FMEA?
The gap between what management thinks customers want and the process specifications.
Concluding there has been an effect/change when there has not.
Failure Modes and Effects Analysis
10 if Almost impossible to detect

37. What are two other names for an Ishikawa diagram?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
A scatterplot.
Critical to quality.
Fishbone - cause-and-effect diagram.

38. Define benchmarking.
Studying firms with the best performance in a particular area.
Hold all input variables constant except one. Observe the response as you vary the single input.
Central Limit Theorem
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.

39. Based on what principal can we use the normal distribution assumptions for SPC?
Workers - machines - materials.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The US national quality award.
Central Limit Theorem

40. In a regression - what does R-square tell you?
Outside.
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 amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Central Limit Theorem

41. F value
They move closer to the center line.
To be a member of a Six Sigma project team.
F_alpha - df(tr) - df (error)
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

42. Name the structure associated with Quality Function Deployment.
A scatterplot.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
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
The House of Quality.

43. What type of risk is associated with Type 1 Error?
Variable.
Producer risk.
Inventory = throughput x flow time.
A diagram that shows the relationships between activities in a project network.

44. Complete this quality phrase: 'Fix the process - not the _____.'
The gap between specifications and how service is performed.
No -- only if the process is also capable.
Represents the behavior of a process
Blame.

45. What is written on the "spines" of a fishbone diagram?
Causes that lead to a particular effect.
The US national quality award.
Kaoru Ishikawa.
A tool that shows performance along key dimensions all at once.

46. Daniel Test
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
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
=sqrt((p*(1-p)/n)
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:

47. Define conformance quality.
Sampling for SPC is done real time.
The degree to which a product meets pre-established standards.
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).
An assertion or conjecture concerning one or more populations

48. What are the four regression assumptions?
It looks to minimize the probability of a failure - or to minimize its effects
Linearity - normality - homoscedasticity - independence.
The primary operating characteristics of a product.
False - because each machine will have different natural tolerances.

49. Advantages of DOE
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
Through producer/consumer negotiation.
No -- the variation also has to be random and "expected."
Prevention and appraisal costs are balanced against internal and external failure.

50. What is the 5S model?
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
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
=sqrt((p*(1-p)/n)
Define - measure - analyze - design - verify.

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