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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. What is an affinity diagram?
Failure Modes and Effects Analysis
If the Response vs. Levels graph if the response lines are not parallel (crossing)
A brainstorming tool that shows the connections between ideas.
An assertion or conjecture concerning one or more populations

2. Define perceived quality (Garvin's framework).
Organize ideas into meaningful categories by recognizing their underlying similarity
F_alpha - df(tr) - df (error)
The manager in charge of a process being improved in a Six Sigma project.
Brand image.

3. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
The primary operating characteristics of a product.
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.
Outside.

4. In a regression - what does the coefficient of the intercept tell you
Failure Modes and Effects Analysis
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
What the value of the dependent variable is when the independent variable is zero.
No -- the variation also has to be random and "expected."

5. What is a spaghetti diagram?
The cycle time required to meet demand.
Concluding there has not been an effect/change when there has.
The degree to which a product meets pre-established standards.
A tool that shows the physical flows through a space.

6. What is the Deming Prize?
50%
To monitor a process when measurement by attribute is used.
Stratify a particular defect type according to logical criteria
The Japanese national quality award.

7. Stratified defect check sheets
=sqrt((p*(1-p)/n)
Pleasing to the senses.
Stratify a particular defect type according to logical criteria
X-bar-bar

8. The Test Statistic (TS)
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
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
A random variable that summarizes the information from the sample(s).
It's good -- but it's still out of control!

9. List two components of prevention cost.
The number of standard deviations some value is from the mean.
Fewer good units to sell - increased variable cost/unit.
Brand image.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

10. To what does the Six in Six Sigma relate?
The target number of standard deviations from the mean for specifications.
Conformance to specifications.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

11. Pareto Analysis
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
An assertion or conjecture concerning one or more populations
Speed - courtesy - competence - and ease of repair.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

12. If you can only collect categorical data - what type of SPC charting can you do?
Attribute.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Brand image.
Lean (or JIT).

13. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Attribute.
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

14. Manual Test for Nomality
Stratify a particular defect type according to logical criteria
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Initiated before or at design concept finalization

15. Failure effect
Method developed by Ishikawa to graphically display the causes of any given problem
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Fitness for use.
Is the consequence of the failure.

16. Simple Regression Analysis (one factor regression model)
X-bar-bar
= 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
Before production starts
Concluding there has been an effect/change when there has not.

17. What type of risk is associated with Type II Error?
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).
Consumer risk.
=sqrt((p*(1-p)/n)
Central Limit Theorem

18. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
95%
Variable.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

19. In a regression - what does the p value of F tell you?
The cycle time required to meet demand.
Producer risk.
No -- if it is not the same - it can only be worse!
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).

20. What is DPMO?
Defects Per Million Opportunities
Hold all input variables constant except one. Observe the response as you vary the single input.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
p-bar - the long-run percent defective.

21. Why do you need two control charts for variables SPC?
Shows the temporal flow of activities in a project network.
Through producer/consumer negotiation.
Because the mean and standard deviation are independent of each other.
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:

22. What is written on the "spines" of a fishbone diagram?
Causes that lead to a particular effect.
Failure Modes and Effects Analysis
The cycle time required to meet demand.
It looks to minimize the probability of a failure - or to minimize its effects

23. FMEA
Conformance to specifications.
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
Shifts - Trends - Repeating patterns - Correlation with known events
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

24. Definition of Interaction
Prevention and appraisal costs are balanced against internal and external failure.
The US national quality award.
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:
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

25. Uses of regression - Control
Failure Modes and Effects Analysis
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
100%
To obtain a certain desirable outcome from the process

26. What are the four perspectives of the Balanced Scorecard?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Attribute
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
Financial - customer - internal process - innovation and learning.

27. When yields decrease - what are the two effects on contribution?
Pleasing to the senses.
Fewer good units to sell - increased variable cost/unit.
= 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 where there is waste in a process.

28. What is a run chart?
A time series plot.
Fractional factorial designs (orthogonal arrays)
Before production starts
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

29. Residual
Lean (or JIT).
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
No -- if it is not the same - it can only be worse!
Not necessarily.

30. What is the center line of an X-bar chart?
Is what induces the failure
50%
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
X-bar-bar

31. What does SIPOC stand for?
Supplier - input - process - output - customer.
Failure Modes and Effects Analysis
A brainstorming tool that shows the connections between ideas.
The House of Quality.

32. What is the role of a green belt?
To be a member of a Six Sigma project team.
Central Limit Theorem
An assertion or conjecture concerning one or more populations
Not necessarily.

33. Process check sheets
Used to create frequency distribution tally sheets
A tool that shows where there is waste in a process.
Lean is waste reduction - Six Sigma is variation reduction.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

34. Risk Priority Number RPN
Assigns scores to weighted criteria for each project under consideration.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Through producer/consumer negotiation.

35. Test for Independence
The House of Quality.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
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
Waste.

36. What is Kaizen?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Pleasing to the senses.
Rapid improvement process.
= yij - y(bar)i --> value minus sum of that treatment (of row)

37. Taguchi's experimental designs are of this type.
Fractional factorial designs (orthogonal arrays)
Failure Modes and Effects Analysis
=sqrt((p*(1-p)/n)
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

38. Your production process meets customer specifications. Is your process in control?
Not necessarily.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
To mentor/coach (and sometimes train) black belts.
Workers - machines - materials.

39. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Lower skill requirements - faster - less chance for error.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
QFD
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).

40. Creating a Run Chart
If the Response vs. Levels graph if the response lines are not parallel (crossing)
A tool that shows where there is waste in a process.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Before production starts

41. Define benchmarking.
Studying firms with the best performance in a particular area.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Shifts - Trends - Repeating patterns - Correlation with known events
p-bar - the long-run percent defective.

42. Define performance quality.
3.4 (assuming 1.5 sigma shift in the mean)
The secondary characteristics of a product; "bells and whistles."
The primary operating characteristics of a product.
X-bar-bar

43. FMEA
Someone who is consistently against virtually everything.
The gap between specifications and how service is performed.
The number of standard deviations some value is from the mean.
It looks to minimize the probability of a failure - or to minimize its effects

44. What type of risk is associated with Type 1 Error?
Producer risk.
The gap between what management thinks customers want and what customers really want.
Brand image.
Prevention - appraisal - internal failure - external failure.

45. With Six Sigma capability - how many defects per million opportunities would you see?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
= yij - y(bar)i --> value minus sum of that treatment (of row)
3.4 (assuming 1.5 sigma shift in the mean)
=sqrt(Σ(x-x-bar)^2)/(n-1))

46. What is muda
Before production starts
Not necessarily.
Variable.
Waste.

47. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Rapid improvement process.
A tool that shows the physical flows through a space.
No -- the variation also has to be random and "expected."
Assigns scores to weighted criteria for each project under consideration.

48. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Pleasing to the senses.
Attribute.
Prevention - appraisal - internal failure - external failure.
Conformance to specifications.

49. What is DMADV?
Fractional factorial designs (orthogonal arrays)
Define - measure - analyze - design - verify.
The ratio of outputs to inputs; 1-scrap.
No -- only if the process is also capable.

50. What is the role of a black belt?
To manage the Six Sigma project.
Fishbone - cause-and-effect diagram.
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
Brand image.

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