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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 muda
Waste.
QFD
Lean (or JIT).
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

2. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Fishbone - cause-and-effect diagram.
The ability of a process to consistently meet customer specifications.
Lower skill requirements - faster - less chance for error.
Initiated before or at design concept finalization

3. Uses of regression
Attribute.
To mentor/coach (and sometimes train) black belts.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The House of Quality.

4. One factor at a time (OFAT)
Concluding there has been an effect/change when there has not.
F_alpha - df(tr) - df (error)
Hold all input variables constant except one. Observe the response as you vary the single input.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

5. What is the Baldrige Award?
The US national quality award.
Taguchi
Causes that lead to a particular effect.
To do a capability study for a non-centered process.

6. Define aesthetic quality.
Brand image.
Define - measure - analyze - improve - control.
Define - measure - analyze - design - verify.
Pleasing to the senses.

7. What are the three main categories of assignable cause?
Concluding there has not been an effect/change when there has.
Workers - machines - materials.
Shows the temporal flow of activities in a project network.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

8. What is the role of a green belt?
F_alpha - df(tr) - df (error)
To be a member of a Six Sigma project team.
X-bar-bar
Sampling for SPC is done real time.

9. Defect location check sheets
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Actual drawings - layouts - maps - etc which show where a defect occurs
No -- if it is not the same - it can only be worse!
=sqrt(Σ(x-x-bar)^2)/(n-1))

10. Affinity Diagrams
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Workers - machines - materials.
Organize ideas into meaningful categories by recognizing their underlying similarity
Fishbone - cause-and-effect diagram.

11. What are the Five Dimensions of Service Quality?
Fitness for use.
The degree to which a product meets pre-established standards.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

12. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
Lean is waste reduction - Six Sigma is variation reduction.
No -- only if the process is also capable.
To monitor a process when measurement by attribute is used.

13. What is a dashboard?
Prevention - appraisal - internal failure - external failure.
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.
A tool that shows performance along key dimensions all at once.

14. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
A scatterplot.
Outside.
The cycle time required to meet demand.
X-bar-bar

15. FMEA
Financial - customer - internal process - innovation and learning.
3.4 (assuming 1.5 sigma shift in the mean)
It looks to minimize the probability of a failure - or to minimize its effects
Fishbone - cause-and-effect diagram.

16. Simple Regression Analysis (one factor regression model)
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 number of standard deviations some value is from the mean.
To do a capability study for a non-centered process.
= 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

17. List two components of prevention cost.
Attribute
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Taguchi
Speed - courtesy - competence - and ease of repair.

18. What is Value Stream Mapping?
Attribute
A tool that shows where there is waste in a process.
Lean (or JIT).
A time series plot.

19. Define serviceability.
Inventory = throughput x flow time.
The cycle time required to meet demand.
The number of standard deviations some value is from the mean.
Speed - courtesy - competence - and ease of repair.

20. When yields decrease - what are the two effects on contribution?
Fewer good units to sell - increased variable cost/unit.
Causes that lead to a particular effect.
Fishbone - cause-and-effect diagram.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

21. The Test Statistic (TS)
Mean time to failure.
An assertion or conjecture concerning one or more populations
A brainstorming tool that shows the connections between ideas.
A random variable that summarizes the information from the sample(s).

22. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Method developed by Ishikawa to graphically display the causes of any given problem
68%
Linearity - normality - homoscedasticity - independence.
Before production starts

23. What does SIPOC stand for?
Variable.
Before production starts
Supplier - input - process - output - customer.
To mentor/coach (and sometimes train) black belts.

24. What size should samples be for attribute SPC?
Initiated before or at design concept finalization
Large enough to find two of the attribute - on average.
Conformance to specifications.
What the value of the dependent variable is when the independent variable is zero.

25. Risk Priority Number RPN
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Producer risk.
Look for the assignable cause of non-random variation.
Taguchi

26. Test for constant variance
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
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.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Fitness for use.

27. What do you do when a process is out of control?
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
Look for the assignable cause of non-random variation.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
The manager in charge of a process being improved in a Six Sigma project.

28. What does the abbreviation UCL stand for?
Taguchi
Conformance to specifications.
A tool that shows where there is waste in a process.
Upper control limit.

29. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
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
Variable.
To manage the Six Sigma project.
Prevention and appraisal costs are balanced against internal and external failure.

30. Explain the difference between technical and functional service quality.
Walter A. Shewhart
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
Before production starts
Technical quality is the "what" of the service; functional quality is the "how."

31. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Lean (or JIT).
Scrap - rework - retest - downtime - yield losses - disposition costs.
Before production starts
F_alpha - df(tr) - df (error)

32. What is the formula for the standard deviation of a proportion?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
=sqrt((p*(1-p)/n)
What the value of the dependent variable is when the independent variable is zero.
0.9^3 or 72.9%

33. Define benchmarking.
Concluding there has been an effect/change when there has not.
The degree to which a product meets pre-established standards.
Studying firms with the best performance in a particular area.
Workers - machines - materials.

34. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Hold all input variables constant except one. Observe the response as you vary the single input.
No -- the variation also has to be random and "expected."
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

35. For what is a p-chart used?
To monitor a process when measurement by attribute is used.
The ability of a process to consistently meet customer specifications.
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
Supplier - input - process - output - customer.

36. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
99.73%
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
100%
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

37. What are the four perspectives of the Balanced Scorecard?
Workers - machines - materials.
Financial - customer - internal process - innovation and learning.
Is what induces the failure
Critical to quality.

38. What are the 5 Ss?
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
Sort - Set in Order - Shine - Standardize - Sustain
Mistake-proofing.
Outside.

39. How does Juran define quality?
Large enough to find two of the attribute - on average.
Brand image.
Fitness for use.
Sort - Set in Order - Shine - Standardize - Sustain

40. Define takt time.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Look for the assignable cause of non-random variation.
The cycle time required to meet demand.
Different types of defects are listed (used for Pareto chart)

41. What does the abbreviation LCL stand for?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Large enough to find two of the attribute - on average.
Lower control limit.
Define - measure - analyze - design - verify.

42. Define yield.
Failure Modes and Effects Analysis
The ratio of outputs to inputs; 1-scrap.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Mean time to replacement.

43. List Garvin's eight dimensions of product quality.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
The US national quality award.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

44. With Six Sigma capability - how many defects per million opportunities would you see?
Can't tell without a Range chart.
Assigns scores to weighted criteria for each project under consideration.
Define - measure - analyze - design - verify.
3.4 (assuming 1.5 sigma shift in the mean)

45. Failure Mode
Rapid improvement process.
Shifts - Trends - Repeating patterns - Correlation with known events
Sort - Set in Order - Shine - Standardize - Sustain
Is the way in which the failure is manifested.

46. TWO-DIMENTIONAL SCATTER PLOT
Rapid improvement process.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

47. In the Service Quality Gap Model - what is Gap 2?
Different types of defects are listed (used for Pareto chart)
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The gap between what management thinks customers want and the process specifications.
The House of Quality.

48. If a three-stage process has 90% yields at each stage - what is the overall yield?
The Japanese national quality award.
Shows the temporal flow of activities in a project network.
To mentor/coach (and sometimes train) black belts.
0.9^3 or 72.9%

49. A process is operating "in control." Does this mean the customer's requirements are met?
Central Limit Theorem
No -- only if the process is also capable.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
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

50. What are the four categories of costs in Juran's framework?
Rapid improvement process.
Prevention - appraisal - internal failure - external failure.
Attribute.
95%

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Six Sigma

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