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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. DOE
The degree to which a product meets pre-established standards.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Shows the temporal flow of activities in a project network.
Assigns scores to weighted criteria for each project under consideration.

2. Creating a Run Chart
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.
Workers - machines - materials.
A time series plot.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

3. Who developed the fishbone diagram?
Central Limit Theorem
Kaoru Ishikawa.
The ability of a process to consistently meet customer specifications.
Walter A. Shewhart

4. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Waste.
68%
Assigns scores to weighted criteria for each project under consideration.
Outside.

5. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
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
Financial - customer - internal process - innovation and learning.
Attribute.

6. Daniel Test
X-bar-bar
No -- the variation also has to be random and "expected."
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:
Used to create frequency distribution tally sheets

7. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
Prevention - appraisal - internal failure - external failure.
Supplier - input - process - output - customer.
Concluding there has not been an effect/change when there has.

8. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
A tool that shows performance along key dimensions all at once.
Technical quality is the "what" of the service; functional quality is the "how."
Variable.

9. For what is an x-bar chart used?
Through producer/consumer negotiation.
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
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
To monitor a process when measurement by variables is used.

10. List two components of external failure.
Sampling for SPC is done real time.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Hold all input variables constant except one. Observe the response as you vary the single input.

11. Define durability.
Because the mean and standard deviation are independent of each other.
Large enough to find two of the attribute - on average.
Mean time to replacement.
100%

12. What are the Five Dimensions of Service Quality?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Not necessarily.
Pleasing to the senses.
Speed - courtesy - competence - and ease of repair.

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

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14. What is a Gage R&R?
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).
Controlling quality at the source.
A diagram that shows the relationships between activities in a project network.
3.4 (assuming 1.5 sigma shift in the mean)

15. What are the four regression assumptions?
A time series plot.
Linearity - normality - homoscedasticity - independence.
Initiated before or at design concept finalization
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

16. With Six Sigma capability - how many defects per million opportunities would you see?
Controlling quality at the source.
3.4 (assuming 1.5 sigma shift in the mean)
Through producer/consumer negotiation.
Consumer risk.

17. Complete this quality phrase: 'Fix the process - not the _____.'
If the Response vs. Levels graph if the response lines are not parallel (crossing)
The US national quality award.
Blame.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

18. Statistical Hypothesis
Shifts - Trends - Repeating patterns - Correlation with known events
An assertion or conjecture concerning one or more populations
Taguchi
Represents the behavior of a process

19. In a Z table - what is Z?
95%
The number of standard deviations some value is from the mean.
Used to create frequency distribution tally sheets
Fewer good units to sell - increased variable cost/unit.

20. If you can only collect categorical data - what type of SPC charting can you do?
Fishbone - cause-and-effect diagram.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
50%
Attribute.

21. Process occurance ranking
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
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
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

22. To what does the Six in Six Sigma relate?
Deming.
Rapid improvement process.
The target number of standard deviations from the mean for specifications.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

23. What is an affinity diagram?
Deming.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
A brainstorming tool that shows the connections between ideas.
Producer risk.

24. What is Type II Error?
Because the mean and standard deviation are independent of each other.
Variable.
Concluding there has not been an effect/change when there has.
Observed variation in response is caused by the input

25. List two components of prevention cost.
Fishbone - cause-and-effect diagram.
A tool that shows performance along key dimensions all at once.
The manager in charge of a process being improved in a Six Sigma project.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

26. What is Kaizen?
X-bar-bar
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Controlling quality at the source.
Rapid improvement process.

27. DFMEA
Waste.
Conformance to specifications.
Initiated before or at design concept finalization
The target number of standard deviations from the mean for specifications.

28. List Garvin's eight dimensions of product quality.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
The House of Quality.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
3.4 (assuming 1.5 sigma shift in the mean)

29. F value
Look for the assignable cause of non-random variation.
F_alpha - df(tr) - df (error)
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Speed - courtesy - competence - and ease of repair.

30. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The number of standard deviations some value is from the mean.
Define - measure - analyze - improve - control.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

31. Based on what principal can we use the normal distribution assumptions for SPC?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Define - measure - analyze - design - verify.
Central Limit Theorem

32. Residual
False - because each machine will have different natural tolerances.
Brand image.
Producer risk.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

33. Define yield.
Stratify a particular defect type according to logical criteria
Deming.
The ratio of outputs to inputs; 1-scrap.
Fishbone - cause-and-effect diagram.

34. If a three-stage process has 90% yields at each stage - what is the overall yield?
Producer risk.
0.9^3 or 72.9%
3.4 (assuming 1.5 sigma shift in the mean)
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

35. PFMEA
0.9^3 or 72.9%
Before production starts
No -- the variation also has to be random and "expected."
Sampling for SPC is done real time.

36. What is DMADV?
Controlling quality at the source.
Define - measure - analyze - design - verify.
Look for the assignable cause of non-random variation.
=sqrt((p*(1-p)/n)

37. Definition of Interaction
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Can't tell without a Range chart.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

38. What is a dashboard?
A tool that shows performance along key dimensions all at once.
Variable.
Pleasing to the senses.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

39. FMEA
Shifts - Trends - Repeating patterns - Correlation with known events
It looks to minimize the probability of a failure - or to minimize its effects
Variable.
To be a member of a Six Sigma project team.

40. What is the role of a master black belt?
Attribute.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
= yij - y(bar)i --> value minus sum of that treatment (of row)
To mentor/coach (and sometimes train) black belts.

41. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Not necessarily.
The Japanese national quality award.
Attribute
Kaoru Ishikawa.

42. What graphical tool is used to show the relationship between two numerical variables?
A scatterplot.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Causes that lead to a particular effect.
Sort - Set in Order - Shine - Standardize - Sustain

43. What happens to control limits on an SPC chart when sample size is increased?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
68%
They move closer to the center line.
Fractional factorial designs (orthogonal arrays)

44. One factor at a time (OFAT)
The target number of standard deviations from the mean for specifications.
A time series plot.
Hold all input variables constant except one. Observe the response as you vary the single input.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

45. What do you do when a process is out of control?
Fractional factorial designs (orthogonal arrays)
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 for the assignable cause of non-random variation.
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

46. What quality guru emphasizes management as a system?
50%
The manager in charge of a process being improved in a Six Sigma project.
Deming.
Is the way in which the failure is manifested.

47. What is a Pareto chart?
To do a capability study for a non-centered process.
Lean is waste reduction - Six Sigma is variation reduction.
A descending order-sorted bar chart with a cumulative percentage line.
Pleasing to the senses.

48. What quality tool formally incorporates the voice of the customer?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
To monitor a process when measurement by variables is used.
Assigns scores to weighted criteria for each project under consideration.
QFD

49. What is Jidoka?
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.
They move closer to the center line.
Controlling quality at the source.

50. Which quality guru developed the concept of loss to society?
Lower control limit.
Taguchi
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
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

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