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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. Define yield.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Organize ideas into meaningful categories by recognizing their underlying similarity
The ratio of outputs to inputs; 1-scrap.
50%

2. What happens to control limits on an SPC chart when sample size is increased?
They move closer to the center line.
Used to create frequency distribution tally sheets
It looks to minimize the probability of a failure - or to minimize its effects
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

3. Who is a process owner?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
The manager in charge of a process being improved in a Six Sigma project.
Mean time to failure.
100%

4. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Attribute
The gap between what is promised and what is delivered.
Shows the temporal flow of activities in a project network.
Deming.

5. Risk Priority Number RPN
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:
To do a capability study for a non-centered process.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
A tool that shows the physical flows through a space.

6. Definition of Interaction
=sqrt(Σ(x-x-bar)^2)/(n-1))
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Kaoru Ishikawa.
The gap between what management thinks customers want and what customers really want.

7. What does the abbreviation LCL stand for?
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
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Lower control limit.
Attribute

8. Your production process meets customer specifications. Is your process in control?
Not necessarily.
Is what induces the failure
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).
X-bar-bar

9. When yields decrease - what are the two effects on contribution?
A random variable that summarizes the information from the sample(s).
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
A diagram that shows the relationships between activities in a project network.
Fewer good units to sell - increased variable cost/unit.

10. What type of risk is associated with Type 1 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
Producer risk.
Prevention - appraisal - internal failure - external failure.
= yij - y(bar)i --> value minus sum of that treatment (of row)

11. Complete this quality phrase: 'Fix the process - not the _____.'
Blame.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
= yij - y(bar)i --> value minus sum of that treatment (of row)
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).

12. If you can only collect categorical data - what type of SPC charting can you do?
The gap between what management thinks customers want and the process specifications.
A tool that shows performance along key dimensions all at once.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Attribute.

13. FMEA
Concluding there has not been an effect/change when there has.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
It looks to minimize the probability of a failure - or to minimize its effects

14. What is an affinity diagram?
Is what induces the failure
Financial - customer - internal process - innovation and learning.
Brand image.
A brainstorming tool that shows the connections between ideas.

15. What does SIPOC stand for?
Not necessarily.
Lower control limit.
A random variable that summarizes the information from the sample(s).
Supplier - input - process - output - customer.

16. DFMEA
Deming.
Producer risk.
Initiated before or at design concept finalization
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

17. Presence of interaction effect
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
It looks to minimize the probability of a failure - or to minimize its effects
The number of standard deviations some value is from the mean.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

18. 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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19. What does Crosby say about benchmarking?
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
A diagram that shows the relationships between activities in a project network.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

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

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21. What is process capability?
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 ability of a process to consistently meet customer specifications.
It's good -- but it's still out of control!
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

22. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Lean (or JIT).
Controlling quality at the source.
F_alpha - df(tr) - df (error)
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

23. What is DMADV?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Controlling quality at the source.
50%
Define - measure - analyze - design - verify.

24. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
F_alpha - df(tr) - df (error)
Outside.
Inventory = throughput x flow time.
The degree to which a product meets pre-established standards.

25. What is the Baldrige Award?
Mean time to failure.
Shifts - Trends - Repeating patterns - Correlation with known events
Is the way in which the failure is manifested.
The US national quality award.

26. List two components of internal failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Hold all input variables constant except one. Observe the response as you vary the single input.
Shows the temporal flow of activities in a project network.
= 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

27. Affinity Diagrams
A random variable that summarizes the information from the sample(s).
To monitor a process when measurement by variables is used.
Initiated before or at design concept finalization
Organize ideas into meaningful categories by recognizing their underlying similarity

28. What is a dashboard?
Shows the temporal flow of activities in a project network.
A tool that shows performance along key dimensions all at once.
Waste.
Because the mean and standard deviation are independent of each other.

29. Histogram by Hand
Central Limit Theorem
Conformance to 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
The cycle time required to meet demand.

30. What is poka yoke?
Assigns scores to weighted criteria for each project under consideration.
Different types of defects are listed (used for Pareto chart)
Mistake-proofing.
What the value of the dependent variable is when the independent variable is zero.

31. What graphical tool is used to show the relationship between two numerical variables?
The Japanese national quality award.
68%
A scatterplot.
Because the mean and standard deviation are independent of each other.

32. What is FMEA?
Concluding there has been an effect/change when there has not.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
68%
Failure Modes and Effects Analysis

33. Define perceived quality (Garvin's framework).
Shows the temporal flow of activities in a project network.
Supplier - input - process - output - customer.
Brand image.
Lean (or JIT).

34. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
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
100%
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

35. To what does the Six in Six Sigma relate?
Central Limit Theorem
The target number of standard deviations from the mean for specifications.
The gap between what is promised and what is delivered.
Supplier - input - process - output - customer.

36. Define benchmarking.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Kaoru Ishikawa.
Studying firms with the best performance in a particular area.
100%

37. What is the formula for standard deviation?
Represents the behavior of a process
=sqrt(Σ(x-x-bar)^2)/(n-1))
No -- only if the process is also capable.
X-bar-bar

38. List two components of prevention cost.
An assertion or conjecture concerning one or more populations
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
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

39. Stratified defect check sheets
=sqrt((p*(1-p)/n)
If the Response vs. Levels graph if the response lines are not parallel (crossing)
The gap between specifications and how service is performed.
Stratify a particular defect type according to logical criteria

40. What quality tool formally incorporates the voice of the customer?
QFD
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
Different types of defects are listed (used for Pareto chart)
To monitor a process when measurement by attribute is used.

41. PFMEA
Financial - customer - internal process - innovation and learning.
Before production starts
Can't tell without a Range chart.
Represents the behavior of a process

42. Taguchi's experimental designs are of this type.
Attribute
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Fractional factorial designs (orthogonal arrays)
To monitor a process when measurement by variables is used.

43. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Producer risk.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Because the mean and standard deviation are independent of each other.
5%

44. What is the 5S model?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
A descending order-sorted bar chart with a cumulative percentage line.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Is the consequence of the failure.

45. Non-random patterns (Run Charts)
Shifts - Trends - Repeating patterns - Correlation with known events
10 for Hazardous without warning 1 for none
To monitor a process when measurement by variables is used.
Not necessarily.

46. What are the four perspectives of the Balanced Scorecard?
Producer risk.
Fishbone - cause-and-effect diagram.
Financial - customer - internal process - innovation and learning.
Assigns scores to weighted criteria for each project under consideration.

47. In the Service Quality Gap Model - what is Gap 3?
Fishbone - cause-and-effect diagram.
An assertion or conjecture concerning one or more populations
The gap between specifications and how service is performed.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

48. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Because the mean and standard deviation are independent of each other.
Variable.
Controlling quality at the source.

49. In a regression - what does the standard error of the estimate tell you?
Fewer good units to sell - increased variable cost/unit.
No -- only if the process is also capable.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Look for the assignable cause of non-random variation.

50. What quality guru emphasizes management as a system?
=sqrt((p*(1-p)/n)
An assertion or conjecture concerning one or more populations
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
Deming.

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