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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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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. Non-random patterns (Run Charts)
Rapid improvement process.
The primary operating characteristics of a product.
Variable.
Shifts - Trends - Repeating patterns - Correlation with known events

2. What type of risk is associated with Type II Error?
Blame.
Consumer risk.
The Japanese national quality award.
0.9^3 or 72.9%

3. In a regression - what does the coefficient of the intercept tell you
p-bar - the long-run percent defective.
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).
What the value of the dependent variable is when the independent variable is zero.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

4. In the Service Quality Gap Model - what is Gap 2?
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
The gap between what management thinks customers want and the process specifications.
Conformance to specifications.
The secondary characteristics of a product; "bells and whistles."

5. DOE
Defects Per Million Opportunities
Before production starts
The manager in charge of a process being improved in a Six Sigma project.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

6. Pareto Analysis
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
F_alpha - df(tr) - df (error)
Studying firms with the best performance in a particular area.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

7. In the Service Quality Gap Model - what is Gap 3?
An assertion or conjecture concerning one or more populations
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The gap between specifications and how service is performed.
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. 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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9. What is DPMO?
Defects Per Million Opportunities
Mean time to replacement.
Linearity - normality - homoscedasticity - independence.
Through producer/consumer negotiation.

10. What is Kaizen?
Because the mean and standard deviation are independent of each other.
3.4 (assuming 1.5 sigma shift in the mean)
Rapid improvement process.
The primary operating characteristics of a product.

11. Taguchi's experimental designs are of this type.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The manager in charge of a process being improved in a Six Sigma project.
Initiated before or at design concept finalization
Fractional factorial designs (orthogonal arrays)

12. One factor at a time (OFAT)
Mean time to replacement.
Hold all input variables constant except one. Observe the response as you vary the single input.
The primary operating characteristics of a product.
Brand image.

13. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
QFD
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Conformance to specifications.

14. In the Service Quality Gap Model - what is Gap 4?
Variable.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Supplier - input - process - output - customer.
The gap between what is promised and what is delivered.

15. What is FMEA?
They move closer to the center line.
Speed - courtesy - competence - and ease of repair.
No -- only if the process is also capable.
Failure Modes and Effects Analysis

16. Test for constant variance
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
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.
Shifts - Trends - Repeating patterns - Correlation with known events
Mistake-proofing.

17. 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?
Define - measure - analyze - improve - control.
50%
An assertion or conjecture concerning one or more populations
False - because each machine will have different natural tolerances.

18. Regression
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).
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Actual drawings - layouts - maps - etc which show where a defect occurs
Represents the behavior of a process

19. List Garvin's eight dimensions of product quality.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Concluding there has not been an effect/change when there has.
Pleasing to the senses.
Fewer good units to sell - increased variable cost/unit.

20. Complete this quality phrase: 'Fix the process - not the _____.'
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
A brainstorming tool that shows the connections between ideas.
Blame.
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

21. For what is an x-bar chart used?
Organize ideas into meaningful categories by recognizing their underlying similarity
Lower control limit.
The gap between specifications and how service is performed.
To monitor a process when measurement by variables is used.

22. What quality tool formally incorporates the voice of the customer?
Define - measure - analyze - improve - control.
QFD
Central Limit Theorem
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

23. What is muda
The degree to which a product meets pre-established standards.
Waste.
100%
= 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

24. Which quality guru developed the concept of loss to society?
QFD
Taguchi
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.
Deming.

25. What are the Five Dimensions of Service Quality?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
3.4 (assuming 1.5 sigma shift in the mean)
= 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 brainstorming tool that shows the connections between ideas.

26. What is the formula for the standard deviation of a proportion?
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)
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

27. Disadvantages of DOE

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28. Define durability.
The manager in charge of a process being improved in a Six Sigma project.
Observed variation in response is caused by the input
Lower control limit.
Mean time to replacement.

29. What type of risk is associated with Type 1 Error?
Observed variation in response is caused by the input
Producer risk.
Because the mean and standard deviation are independent of each other.
Workers - machines - materials.

30. What is a run chart?
A time series plot.
Lean (or JIT).
Lean is waste reduction - Six Sigma is variation reduction.
A tool that shows where there is waste in a process.

31. Process check sheets
Used to create frequency distribution tally sheets
Concluding there has been an effect/change when there has not.
Taguchi
10 if Almost impossible to detect

32. What does the abbreviation UCL stand for?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Through producer/consumer negotiation.
The gap between specifications and how service is performed.
Upper control limit.

33. Who developed the fishbone diagram?
To do a capability study for a non-centered process.
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
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Kaoru Ishikawa.

34. What is a network diagram?
A diagram that shows the relationships between activities in a project network.
A scatterplot.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Fractional factorial designs (orthogonal arrays)

35. TWO-DIMENTIONAL SCATTER PLOT
The House of Quality.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Shows the temporal flow of activities in a project network.
Assigns scores to weighted criteria for each project under consideration.

36. Process occurance ranking
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Sampling for SPC is done real time.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

37. What does DMAIC stand for?
Walter A. Shewhart
Define - measure - analyze - improve - control.
Stratify a particular defect type according to logical criteria
Reliability - Assurance - Responsiveness - Tangibles - Empathy

38. Your production process meets customer specifications. Is your process in control?
Not necessarily.
Can't tell without a Range chart.
The secondary characteristics of a product; "bells and whistles."
0.9^3 or 72.9%

39. What does the abbreviation LCL stand for?
Lower control limit.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
No -- the variation also has to be random and "expected."
Look for the assignable cause of non-random variation.

40. What is Little's Law?
To obtain a certain desirable outcome from the process
A time series plot.
Inventory = throughput x flow time.
No -- only if the process is also capable.

41. What is a CAVE man?
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
Someone who is consistently against virtually everything.
A time series plot.
Lower skill requirements - faster - less chance for error.

42. If a three-stage process has 90% yields at each stage - what is the overall yield?
Central Limit Theorem
Define - measure - analyze - design - verify.
Waste.
0.9^3 or 72.9%

43. What graphical tool is used to show the relationship between two numerical variables?
A scatterplot.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
10 if Almost impossible to detect
Mean time to replacement.

44. Advantages of DOE
Upper control limit.
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
Different types of defects are listed (used for Pareto chart)
F_alpha - df(tr) - df (error)

45. Failure Mode
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).
Actual drawings - layouts - maps - etc which show where a defect occurs
Is the way in which the failure is manifested.
To manage the Six Sigma project.

46. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Supplier - input - process - output - customer.
Sampling for SPC is done real time.
The Japanese national quality award.
3.4 (assuming 1.5 sigma shift in the mean)

47. What is the Baldrige Award?
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).
Fractional factorial designs (orthogonal arrays)
The US national quality award.
To obtain a certain desirable outcome from the process

48. In the Service Quality Gap Model - what is Gap 5?
The gap between what customers expect and the service they receive.
Prevention - appraisal - internal failure - external failure.
99.73%
The gap between what is promised and what is delivered.

49. One factor at a time (OFAT)
=sqrt(Σ(x-x-bar)^2)/(n-1))
Someone who is consistently against virtually everything.
Observed variation in response is caused by the input
Shows the temporal flow of activities in a project network.

50. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
The number of standard deviations some value is from the mean.
Fishbone - cause-and-effect diagram.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
100%

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