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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. F value
The gap between what is promised and what is delivered.
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
Is the way in which the failure is manifested.

2. FMEA
=sqrt(Σ(x-x-bar)^2)/(n-1))
The gap between specifications and how service is performed.
100%
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

3. Who developed the fishbone diagram?
= yij - y(bar)i --> value minus sum of that treatment (of row)
A tool that shows where there is waste in a process.
Kaoru Ishikawa.
Causes that lead to a particular effect.

4. Explain the difference between technical and functional service quality.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Prevention and appraisal costs are balanced against internal and external failure.
Technical quality is the "what" of the service; functional quality is the "how."
False - because each machine will have different natural tolerances.

5. Which type of SPC measurement is more precise - variable or attribute?
Variable.
Before production starts
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

6. What is poka yoke?
Mean time to failure.
Mistake-proofing.
Look for the assignable cause of non-random variation.
Because the mean and standard deviation are independent of each other.

7. Daniel Test
To monitor a process when measurement by variables is used.
Upper control limit.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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:

8. List two components of internal failure.
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.
Studying firms with the best performance in a particular area.
Actual drawings - layouts - maps - etc which show where a defect occurs

9. What are the three main categories of assignable cause?
Actual drawings - layouts - maps - etc which show where a defect occurs
Workers - machines - materials.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Upper control limit.

10. What is Type II Error?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
50%
Concluding there has not been an effect/change when there has.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

11. Detection Criteria Ranking
Concluding there has been an effect/change when there has not.
X-bar-bar
10 if Almost impossible to detect
Central Limit Theorem

12. What graphical tool is used to show the relationship between two numerical variables?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
=sqrt((p*(1-p)/n)
A scatterplot.
No -- if it is not the same - it can only be worse!

13. Regression Analysis
Observed variation in response is caused by the input
The ability of a process to consistently meet customer specifications.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Controlling quality at the source.

14. What is a network diagram?
Deming.
Inventory = throughput x flow time.
A diagram that shows the relationships between activities in a project network.
Before production starts

15. If a three-stage process has 90% yields at each stage - what is the overall yield?
The US national quality award.
Large enough to find two of the attribute - on average.
0.9^3 or 72.9%
No -- only if the process is also capable.

16. What are two other names for an Ishikawa diagram?
They move closer to the center line.
No -- the variation also has to be random and "expected."
Fishbone - cause-and-effect diagram.
Concluding there has been an effect/change when there has not.

17. What is the center line of an X-bar chart?
The gap between what customers expect and the service they receive.
X-bar-bar
5%
Lower skill requirements - faster - less chance for error.

18. Design of Experiments (DOE) approach
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
To manage the Six Sigma project.
Define - measure - analyze - design - verify.
Lower control limit.

19. When is Cpk used?
Mistake-proofing.
Brand image.
To do a capability study for a non-centered process.
Variable.

20. What is the formula for the standard deviation of a proportion?
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
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
=sqrt((p*(1-p)/n)
If the Response vs. Levels graph if the response lines are not parallel (crossing)

21. What is a histogram?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Fractional factorial designs (orthogonal arrays)
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Observed variation in response is caused by the input

22. One factor at a time (OFAT)
Failure Modes and Effects Analysis
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Rapid improvement process.
Observed variation in response is caused by the input

23. Uses of regression
3.4 (assuming 1.5 sigma shift in the mean)
Assigns scores to weighted criteria for each project under consideration.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Large enough to find two of the attribute - on average.

24. What is a Pareto chart?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
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:
Variable.
A descending order-sorted bar chart with a cumulative percentage line.

25. DOE
Sampling for SPC is done real time.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

26. What is the role of a master black belt?
Lower control limit.
10 if Almost impossible to detect
To mentor/coach (and sometimes train) black belts.
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

27. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
10 if Almost impossible to detect
No -- the variation also has to be random and "expected."
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Mean time to failure.

28. What does a project prioritization matrix do?
The gap between what customers expect and the service they receive.
Is what induces the failure
They move closer to the center line.
Assigns scores to weighted criteria for each project under consideration.

29. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
To be a member of a Six Sigma project team.
A tool that shows where there is waste in a process.
The gap between what management thinks customers want and the process specifications.

30. What happens to control limits on an SPC chart when sample size is increased?
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
Workers - machines - materials.
Through producer/consumer negotiation.
They move closer to the center line.

31. What is the role of a black belt?
Attribute
To manage the Six Sigma project.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Pleasing to the senses.

32. In a regression - what does the standard error of the estimate tell you?
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
Scrap - rework - retest - downtime - yield losses - disposition costs.
No -- the variation also has to be random and "expected."
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

33. Failure effect
Is the consequence of the failure.
Someone who is consistently against virtually everything.
The ability of a process to consistently meet customer specifications.
Prevention - appraisal - internal failure - external failure.

34. One factor at a time (OFAT)
To be a member of a Six Sigma project team.
It looks to minimize the probability of a failure - or to minimize its effects
Hold all input variables constant except one. Observe the response as you vary the single input.
Is the way in which the failure is manifested.

35. Advantages of DOE
Not necessarily.
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
If the Response vs. Levels graph if the response lines are not parallel (crossing)
10 if Almost impossible to detect

36. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Lean (or JIT).
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
Causes that lead to a particular effect.
Lower control limit.

37. What is Kaizen?
Someone who is consistently against virtually everything.
Rapid improvement process.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Outside.

38. What do you do when a process is out of control?
Look for the assignable cause of non-random variation.
To monitor a process when measurement by variables is used.
Shows the temporal flow of activities in a project network.
Upper control limit.

39. What quality guru emphasizes management as a system?
Fishbone - cause-and-effect diagram.
Technical quality is the "what" of the service; functional quality is the "how."
Deming.
=sqrt((p*(1-p)/n)

40. What is FMEA?
Failure Modes and Effects Analysis
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Because the mean and standard deviation are independent of each other.
Shows the temporal flow of activities in a project network.

41. Process check sheets
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Someone who is consistently against virtually everything.
Used to create frequency distribution tally sheets
Walter A. Shewhart

42. Presence of interaction effect
An assertion or conjecture concerning one or more populations
Sampling for SPC is done real time.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Deming.

43. In a Z table - what is Z?
Fractional factorial designs (orthogonal arrays)
Define - measure - analyze - design - verify.
The number of standard deviations some value is from the mean.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

44. When yields decrease - what are the two effects on contribution?
A random variable that summarizes the information from the sample(s).
Variable.
Prevention and appraisal costs are balanced against internal and external failure.
Fewer good units to sell - increased variable cost/unit.

45. List two components of external failure.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Mean time to replacement.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Outside.

46. Risk Priority Number RPN
Look for the assignable cause of non-random variation.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
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.

47. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
The House of Quality.
The primary operating characteristics of a product.
Inventory = throughput x flow time.

48. Test for Independence
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
A random variable that summarizes the information from the sample(s).
Is the way in which the failure is manifested.

49. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Variable.
Sort - Set in Order - Shine - Standardize - Sustain
A time series plot.
Someone who is consistently against virtually everything.

50. What is Type 1 Error?
Prevention - appraisal - internal failure - external failure.
0.9^3 or 72.9%
Concluding there has been an effect/change when there has not.
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

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