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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 inventory approach contributes to process quality by "lowering the river to find the rocks?"
Lean (or JIT).
Because the mean and standard deviation are independent of each other.
Failure Modes and Effects Analysis
Speed - courtesy - competence - and ease of repair.

2. What is a run chart?
Attribute.
A time series plot.
Actual drawings - layouts - maps - etc which show where a defect occurs
A brainstorming tool that shows the connections between ideas.

3. What is the Baldrige Award?
The US national quality award.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Hold all input variables constant except one. Observe the response as you vary the single input.
Upper control limit.

4. In the Service Quality Gap Model - what is Gap 1?
The gap between what management thinks customers want and what customers really want.
0.9^3 or 72.9%
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
Central Limit Theorem

5. Residual
Is the way in which the failure is manifested.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Someone who is consistently against virtually everything.

6. What is a network diagram?
X-bar-bar
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
A diagram that shows the relationships between activities in a project network.
Look for the assignable cause of non-random variation.

7. What does the abbreviation UCL stand for?
Upper control limit.
A descending order-sorted bar chart with a cumulative percentage line.
The House of Quality.
F_alpha - df(tr) - df (error)

8. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Is the consequence of the failure.
Brand image.
Scrap - rework - retest - downtime - yield losses - disposition costs.
99.73%

9. What is DPMO?
The ratio of outputs to inputs; 1-scrap.
Defects Per Million Opportunities
Failure Modes and Effects Analysis
To monitor a process when measurement by variables is used.

10. Defect location check sheets
Actual drawings - layouts - maps - etc which show where a defect occurs
Defects Per Million Opportunities
Failure Modes and Effects Analysis
Sort - Set in Order - Shine - Standardize - Sustain

11. In a Z table - what is Z?
The number of standard deviations some value is from the mean.
Initiated before or at design concept finalization
99.73%
3.4 (assuming 1.5 sigma shift in the mean)

12. Name the structure associated with Quality Function Deployment.
The House of Quality.
False - because each machine will have different natural tolerances.
A diagram that shows the relationships between activities in a project network.
Stratify a particular defect type according to logical criteria

13. What is process capability?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Supplier - input - process - output - customer.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The ability of a process to consistently meet customer specifications.

14. Stratified defect check sheets
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 ability of a process to consistently meet customer specifications.
Stratify a particular defect type according to logical criteria
To monitor a process when measurement by variables is used.

15. Explain the difference between technical and functional service quality.
Lower skill requirements - faster - less chance for error.
Technical quality is the "what" of the service; functional quality is the "how."
X-bar-bar
Hold all input variables constant except one. Observe the response as you vary the single input.

16. Risk Priority Number RPN
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Fractional factorial designs (orthogonal arrays)
=sqrt(Σ(x-x-bar)^2)/(n-1))
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

17. Pareto Analysis
The number of standard deviations some value is from the mean.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Walter A. Shewhart
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

18. What quality tool formally incorporates the voice of the customer?
Define - measure - analyze - improve - control.
QFD
Hold all input variables constant except one. Observe the response as you vary the single input.
Upper control limit.

19. Your production process meets customer specifications. Is your process in control?
Rapid improvement process.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Not necessarily.
Waste.

20. Detection Criteria Ranking
10 if Almost impossible to detect
Is the way in which the failure is manifested.
Define - measure - analyze - design - verify.
The ratio of outputs to inputs; 1-scrap.

21. ANOVA

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22. Defect check sheets
Different types of defects are listed (used for Pareto chart)
It's good -- but it's still out of control!
An assertion or conjecture concerning one or more populations
A tool that shows where there is waste in a process.

23. What are two other names for an Ishikawa diagram?
50%
Look for the assignable cause of non-random variation.
Fishbone - cause-and-effect diagram.
Studying firms with the best performance in a particular area.

24. When yields decrease - what are the two effects on contribution?
Taguchi
Central Limit Theorem
Fewer good units to sell - increased variable cost/unit.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

25. Affinity Diagrams
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Fitness for use.
Organize ideas into meaningful categories by recognizing their underlying similarity
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

26. What is a CAVE man?
Sort - Set in Order - Shine - Standardize - Sustain
The secondary characteristics of a product; "bells and whistles."
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
Someone who is consistently against virtually everything.

27. Statistical Hypothesis
An assertion or conjecture concerning one or more populations
It's good -- but it's still out of control!
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

28. What is the role of a master black belt?
To mentor/coach (and sometimes train) black belts.
Because the mean and standard deviation are independent of each other.
What the value of the dependent variable is when the independent variable is zero.
QFD

29. What quality guru emphasizes management as a system?
Prevention - appraisal - internal failure - external failure.
= yij - y(bar)i --> value minus sum of that treatment (of row)
The target number of standard deviations from the mean for specifications.
Deming.

30. Definition of Interaction
The primary operating characteristics of a product.
Observed variation in response is caused by the input
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
100%

31. Residual(eij)
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
= yij - y(bar)i --> value minus sum of that treatment (of row)
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The US national quality award.

32. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The gap between specifications and how service is performed.
Supplier - input - process - output - customer.
Outside.

33. FMEA
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
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.
0.9^3 or 72.9%

34. Simple Regression Analysis (one factor regression model)
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
= 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
Pleasing to the senses.
p-bar - the long-run percent defective.

35. If a three-stage process has 90% yields at each stage - what is the overall yield?
A time series plot.
= yij - y(bar)i --> value minus sum of that treatment (of row)
0.9^3 or 72.9%
The Japanese national quality award.

36. What is written on the "spines" of a fishbone diagram?
Used to create frequency distribution tally sheets
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Causes that lead to a particular effect.
Linearity - normality - homoscedasticity - independence.

37. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Central Limit Theorem
5%
68%
Through producer/consumer negotiation.

38. 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).
Scrap - rework - retest - downtime - yield losses - disposition costs.
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.
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).

39. What type of risk is associated with Type II Error?
Lower control limit.
100%
Consumer risk.
68%

40. What is a Gantt chart?
Shows the temporal flow of activities in a project network.
Mean time to failure.
The target number of standard deviations from the mean for specifications.
Variable.

41. How are LQL and AQL determined in an acceptance sampling plan?
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
Upper control limit.
10 if Almost impossible to detect
Through producer/consumer negotiation.

42. What is Type II Error?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Concluding there has not been an effect/change when there has.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Variable.

43. What are the four regression assumptions?
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
False - because each machine will have different natural tolerances.
Linearity - normality - homoscedasticity - independence.
A tool that shows performance along key dimensions all at once.

44. How does Juran define quality?
Waste.
Fitness for use.
Is what induces the failure
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

45. Cause and Effect Diagrams
The primary operating characteristics of a product.
Method developed by Ishikawa to graphically display the causes of any given problem
The gap between what is promised and what is delivered.
Different types of defects are listed (used for Pareto chart)

46. What is CTQ?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
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:
Critical to quality.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

47. List two appraisal costs.
Stratify a particular defect type according to logical criteria
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Financial - customer - internal process - innovation and learning.
Consumer risk.

48. Failure cause
Is what induces the failure
The gap between specifications and how service is performed.
The primary operating characteristics of a product.
Define - measure - analyze - improve - control.

49. What does the abbreviation LCL stand for?
99.73%
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Lower control limit.
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:

50. List two components of prevention cost.
Not necessarily.
No -- only if the process is also capable.
Walter A. Shewhart
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

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