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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. Define perceived quality (Garvin's framework).
Brand image.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The gap between what is promised and what is delivered.
Is the consequence of the failure.

2. What is the formula for the standard deviation of a proportion?
X-bar-bar
=sqrt((p*(1-p)/n)
To monitor a process when measurement by attribute is used.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

3. What is Value Stream Mapping?
X-bar-bar
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Prevention - appraisal - internal failure - external failure.
A tool that shows where there is waste in a process.

4. What is a run chart?
What the value of the dependent variable is when the independent variable is zero.
Stratify a particular defect type according to logical criteria
95%
A time series plot.

5. What happens to control limits on an SPC chart when sample size is increased?
95%
They move closer to the center line.
Fishbone - cause-and-effect diagram.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

6. If you have calculated a Cpk - should you also calculate a Cp?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Linearity - normality - homoscedasticity - independence.
They move closer to the center line.

7. What quality tool formally incorporates the voice of the customer?
QFD
99.73%
The gap between what is promised and what is delivered.
Lean is waste reduction - Six Sigma is variation reduction.

8. Which quality guru developed the concept of loss to society?
Sort - Set in Order - Shine - Standardize - Sustain
Shifts - Trends - Repeating patterns - Correlation with known events
Through producer/consumer negotiation.
Taguchi

9. 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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10. Disadvantages of DOE

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11. DOE
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
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
Method developed by Ishikawa to graphically display the causes of any given problem
Is the way in which the failure is manifested.

12. What is DMADV?
Scrap - rework - retest - downtime - yield losses - disposition costs.
Financial - customer - internal process - innovation and learning.
Define - measure - analyze - design - verify.
Someone who is consistently against virtually everything.

13. If a three-stage process has 90% yields at each stage - what is the overall yield?
0.9^3 or 72.9%
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

14. What is written on the "spines" of a fishbone diagram?
What the value of the dependent variable is when the independent variable is zero.
Attribute
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
Causes that lead to a particular effect.

15. What type of risk is associated with Type 1 Error?
Producer risk.
False - because each machine will have different natural tolerances.
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
=sqrt((p*(1-p)/n)

16. Non-random patterns (Run Charts)
Is what induces the failure
The secondary characteristics of a product; "bells and whistles."
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
Shifts - Trends - Repeating patterns - Correlation with known events

17. Who first studied randomness in industrial processes
Walter A. Shewhart
Deming.
The target number of standard deviations from the mean for specifications.
Attribute

18. If a Cp shows that a process is not capable - should you calculate Cpk?
No -- if it is not the same - it can only be worse!
Stratify a particular defect type according to logical criteria
To manage the Six Sigma project.
Mean time to failure.

19. Define yield.
95%
Fractional factorial designs (orthogonal arrays)
An assertion or conjecture concerning one or more populations
The ratio of outputs to inputs; 1-scrap.

20. What does DMAIC stand for?
Define - measure - analyze - improve - control.
Pleasing to the senses.
Lower control limit.
The manager in charge of a process being improved in a Six Sigma project.

21. When yields decrease - what are the two effects on contribution?
Stratify a particular defect type according to logical criteria
Define - measure - analyze - improve - control.
Financial - customer - internal process - innovation and learning.
Fewer good units to sell - increased variable cost/unit.

22. FMEA
Scrap - rework - retest - downtime - yield losses - disposition costs.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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
Financial - customer - internal process - innovation and learning.

23. In a regression - what does the coefficient of the intercept tell you
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
What the value of the dependent variable is when the independent variable is zero.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

24. Daniel Test
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
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
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:
Reliability - Assurance - Responsiveness - Tangibles - Empathy

25. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Pleasing to the senses.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Conformance to specifications.
Through producer/consumer negotiation.

26. Does it ever make sense to accept a job when a process is incapable?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Organize ideas into meaningful categories by recognizing their underlying similarity
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
A brainstorming tool that shows the connections between ideas.

27. Test for constant variance
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.
What the value of the dependent variable is when the independent variable is zero.
Method developed by Ishikawa to graphically display the causes of any given problem
Look for the assignable cause of non-random variation.

28. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Attribute
Outside.
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
Through producer/consumer negotiation.

29. In a Z table - what is Z?
Represents the behavior of a process
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Is the way in which the failure is manifested.
The number of standard deviations some value is from the mean.

30. DFMEA
Initiated before or at design concept finalization
Technical quality is the "what" of the service; functional quality is the "how."
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Workers - machines - materials.

31. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
Assigns scores to weighted criteria for each project under consideration.
3.4 (assuming 1.5 sigma shift in the mean)
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

32. 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?
Financial - customer - internal process - innovation and learning.
Assigns scores to weighted criteria for each project under consideration.
False - because each machine will have different natural tolerances.
Define - measure - analyze - improve - control.

33. Which type of SPC measurement is more precise - variable or attribute?
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
Blame.
Financial - customer - internal process - innovation and learning.
Variable.

34. For what is a p-chart used?
To monitor a process when measurement by attribute is used.
To do a capability study for a non-centered process.
The target number of standard deviations from the mean for specifications.
Conformance to specifications.

35. Presence of interaction effect
To obtain a certain desirable outcome from the process
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
If the Response vs. Levels graph if the response lines are not parallel (crossing)
No -- if it is not the same - it can only be worse!

36. To what does the Six in Six Sigma relate?
The target number of standard deviations from the mean for 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
The manager in charge of a process being improved in a Six Sigma project.
Lean (or JIT).

37. Define benchmarking.
Can't tell without a Range chart.
= 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
Studying firms with the best performance in a particular area.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

38. Define serviceability.
A tool that shows performance along key dimensions all at once.
Prevention and appraisal costs are balanced against internal and external failure.
Speed - courtesy - competence - and ease of repair.
Variable.

39. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The House of Quality.
Variable.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

40. What does the abbreviation UCL stand for?
Linearity - normality - homoscedasticity - independence.
A diagram that shows the relationships between activities in a project network.
Upper control limit.
Fitness for use.

41. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Lean is waste reduction - Six Sigma is variation reduction.
Lean (or JIT).
Observed variation in response is caused by the input
Prevention and appraisal costs are balanced against internal and external failure.

42. What is the Deming Prize?
The Japanese national quality award.
3.4 (assuming 1.5 sigma shift in the mean)
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Failure Modes and Effects Analysis

43. What does Crosby say about benchmarking?
0.9^3 or 72.9%
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.
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).

44. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
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
To obtain a certain desirable outcome from the process
95%
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

45. In the Service Quality Gap Model - what is Gap 1?
Financial - customer - internal process - innovation and learning.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The gap between what management thinks customers want and what customers really want.

46. Who developed the fishbone diagram?
Lower skill requirements - faster - less chance for error.
Prevention and appraisal costs are balanced against internal and external failure.
Mean time to replacement.
Kaoru Ishikawa.

47. What do you do when a process is out of control?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Taguchi
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Look for the assignable cause of non-random variation.

48. The Test Statistic (TS)
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.
=sqrt((p*(1-p)/n)
Brand image.
A random variable that summarizes the information from the sample(s).

49. What is the center line of a p-chart?
p-bar - the long-run percent defective.
Large enough to find two of the attribute - on average.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The gap between specifications and how service is performed.

50. Manual Test for Nomality
Fewer good units to sell - increased variable cost/unit.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Not necessarily.

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