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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.
Don't refresh. All questions and answers are randomly picked and ordered every time you load a test.

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. Based on what principal can we use the normal distribution assumptions for SPC?
Is the way in which the failure is manifested.
Lower control limit.
Central Limit Theorem
To manage the Six Sigma project.

2. F value
Pleasing to the senses.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
F_alpha - df(tr) - df (error)
Method developed by Ishikawa to graphically display the causes of any given problem

3. Failure cause
Mean time to failure.
Walter A. Shewhart
Is what induces the failure
Sampling for SPC is done real time.

4. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
It's good -- but it's still out of control!
The Japanese national quality award.
Variable.
X-bar-bar

5. Residual(eij)
= yij - y(bar)i --> value minus sum of that treatment (of row)
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The House of Quality.

6. What is Value Stream Mapping?
To monitor a process when measurement by attribute is used.
A time series plot.
To do a capability study for a non-centered process.
A tool that shows where there is waste in a process.

7. What is DMADV?
It looks to minimize the probability of a failure - or to minimize its effects
Prevention - appraisal - internal failure - external failure.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Define - measure - analyze - design - verify.

8. Histogram by Hand
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
Scrap - rework - retest - downtime - yield losses - disposition costs.
QFD
Shifts - Trends - Repeating patterns - Correlation with known events

9. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Lean is waste reduction - Six Sigma is variation reduction.
Prevention and appraisal costs are balanced against internal and external failure.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Attribute

10. If a three-stage process has 90% yields at each stage - what is the overall yield?
Studying firms with the best performance in a particular area.
Fractional factorial designs (orthogonal arrays)
0.9^3 or 72.9%
Shifts - Trends - Repeating patterns - Correlation with known events

11. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
A diagram that shows the relationships between activities in a project network.
Lower skill requirements - faster - less chance for error.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

12. List Garvin's eight dimensions of product quality.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Prevention and appraisal costs are balanced against internal and external failure.
Critical to quality.

13. What is a network diagram?
A diagram that shows the relationships between activities in a project network.
Studying firms with the best performance in a particular area.
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).
Initiated before or at design concept finalization

14. Pareto Analysis
Deming.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The cycle time required to meet demand.

15. What is FMEA?
The ability of a process to consistently meet customer specifications.
Failure Modes and Effects Analysis
The target number of standard deviations from the mean for specifications.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

16. Uses of regression - Control
It's good -- but it's still out of control!
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).
To obtain a certain desirable outcome from the process
The degree to which a product meets pre-established standards.

17. Affinity Diagrams
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
A tool that shows where there is waste in a process.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
To manage the Six Sigma project.

18. What is a Pareto chart?
Because the mean and standard deviation are independent of each other.
To do a capability study for a non-centered process.
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).
A descending order-sorted bar chart with a cumulative percentage line.

19. Defect check sheets
Different types of defects are listed (used for Pareto chart)
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Mistake-proofing.
Conformance to specifications.

20. How does Juran define quality?
Fitness for use.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Kaoru Ishikawa.
Supplier - input - process - output - customer.

21. What graphical tool is used to show the relationship between two numerical variables?
95%
The number of standard deviations some value is from the mean.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
A scatterplot.

22. To what does the Six in Six Sigma relate?
Consumer risk.
Variable.
Mean time to failure.
The target number of standard deviations from the mean for specifications.

23. Process check sheets
Pleasing to the senses.
Used to create frequency distribution tally sheets
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:
Define - measure - analyze - design - verify.

24. The Test Statistic (TS)
A random variable that summarizes the information from the sample(s).
Attribute.
Concluding there has not been an effect/change when there has.
Because the mean and standard deviation are independent of each other.

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

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26. In the Service Quality Gap Model - what is Gap 5?
Define - measure - analyze - improve - control.
The gap between what customers expect and the service they receive.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
A scatterplot.

27. Affinity Diagrams
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Brand image.
Because the mean and standard deviation are independent of each other.
Organize ideas into meaningful categories by recognizing their underlying similarity

28. Which type of SPC measurement is more precise - variable or attribute?
Because the mean and standard deviation are independent of each other.
A descending order-sorted bar chart with a cumulative percentage line.
Variable.
Fewer good units to sell - increased variable cost/unit.

29. What is the Deming Prize?
The Japanese national quality award.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Prevention - appraisal - internal failure - external failure.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

30. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
The gap between what customers expect and the service they receive.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
100%
Walter A. Shewhart

31. What is written on the "spines" of a fishbone diagram?
Causes that lead to a particular effect.
Define - measure - analyze - design - verify.
A random variable that summarizes the information from the sample(s).
Represents the behavior of a process

32. Regression
Look for the assignable cause of non-random variation.
The degree to which a product meets pre-established standards.
They move closer to the center line.
Represents the behavior of a process

33. In the Service Quality Gap Model - what is Gap 2?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The gap between what management thinks customers want and the process specifications.
3.4 (assuming 1.5 sigma shift in the mean)
Prevention and appraisal costs are balanced against internal and external failure.

34. Stratified defect check sheets
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
Before production starts
Shows the temporal flow of activities in a project network.
Stratify a particular defect type according to logical criteria

35. Define product reliability.
Critical to quality.
Lower control limit.
A diagram that shows the relationships between activities in a project network.
Mean time to failure.

36. What is the center line of an X-bar chart?
X-bar-bar
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
Reliability - Assurance - Responsiveness - Tangibles - Empathy

37. When yields decrease - what are the two effects on contribution?
Central Limit Theorem
Fewer good units to sell - increased variable cost/unit.
Observed variation in response is caused by the input
Lean is waste reduction - Six Sigma is variation reduction.

38. What does the abbreviation LCL stand for?
To monitor a process when measurement by variables is used.
Lower control limit.
Shifts - Trends - Repeating patterns - Correlation with known events
Prevention - appraisal - internal failure - external failure.

39. What is a histogram?
It's good -- but it's still out of control!
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Technical quality is the "what" of the service; functional quality is the "how."
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

40. What size should samples be for attribute SPC?
Fishbone - cause-and-effect diagram.
Controlling quality at the source.
The gap between what management thinks customers want and what customers really want.
Large enough to find two of the attribute - on average.

41. In a regression - what does the p value of F tell you?
No -- only if the process is also capable.
Lean is waste reduction - Six Sigma is variation reduction.
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).
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

42. Definition of Interaction
X-bar-bar
Concluding there has been an effect/change when there has not.
A scatterplot.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

43. Test for constant variance
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
To mentor/coach (and sometimes train) black belts.
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
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.

44. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
No -- the variation also has to be random and "expected."
Before production starts
What the value of the dependent variable is when the independent variable is zero.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

45. In a Z table - what is Z?
F_alpha - df(tr) - df (error)
The number of standard deviations some value is from the mean.
Mistake-proofing.
Variable.

46. 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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47. Presence of interaction effect
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
To manage the Six Sigma project.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
No -- only if the process is also capable.

48. Statistical Hypothesis
To manage the Six Sigma project.
A random variable that summarizes the information from the sample(s).
3.4 (assuming 1.5 sigma shift in the mean)
An assertion or conjecture concerning one or more populations

49. What is DPMO?
To monitor a process when measurement by attribute is used.
Defects Per Million Opportunities
Pleasing to the senses.
Studying firms with the best performance in a particular area.

50. List two components of prevention cost.
A diagram that shows the relationships between activities in a project network.
A time series plot.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
= yij - y(bar)i --> value minus sum of that treatment (of row)

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Six Sigma

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