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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. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The number of standard deviations some value is from the mean.
95%
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

2. 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?
It's good -- but it's still out of control!
Prevention - appraisal - internal failure - external failure.
=sqrt(Σ(x-x-bar)^2)/(n-1))
False - because each machine will have different natural tolerances.

3. DFMEA
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Taguchi
A tool that shows performance along key dimensions all at once.
Initiated before or at design concept finalization

4. What is the Deming Prize?
The Japanese national quality award.
Stratify a particular defect type according to logical criteria
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The manager in charge of a process being improved in a Six Sigma project.

5. In a regression - what does the coefficient of the intercept tell you
What the value of the dependent variable is when the independent variable is zero.
Taguchi
To mentor/coach (and sometimes train) black belts.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

6. What does SIPOC stand for?
Studying firms with the best performance in a particular area.
Supplier - input - process - output - customer.
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
F_alpha - df(tr) - df (error)

7. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Sampling for SPC is done real time.
Critical to quality.
To mentor/coach (and sometimes train) black belts.
Scrap - rework - retest - downtime - yield losses - disposition costs.

8. Statistical Hypothesis
An assertion or conjecture concerning one or more populations
The House of Quality.
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

9. Define conformance quality.
The degree to which a product meets pre-established standards.
To do a capability study for a non-centered process.
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).
Taguchi

10. In a regression - what does the standard error of the estimate tell you?
The gap between specifications and how service is performed.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
To be a member of a Six Sigma project team.

11. Process check sheets
Before production starts
Rapid improvement process.
The secondary characteristics of a product; "bells and whistles."
Used to create frequency distribution tally sheets

12. PFMEA
The Japanese national quality award.
Mean time to replacement.
50%
Before production starts

13. What is the Baldrige Award?
Consumer risk.
Large enough to find two of the attribute - on average.
The number of standard deviations some value is from the mean.
The US national quality award.

14. What does the abbreviation LCL stand for?
Lower control limit.
Fewer good units to sell - increased variable cost/unit.
Walter A. Shewhart
A random variable that summarizes the information from the sample(s).

15. What is the role of a green belt?
The gap between what is promised and what is delivered.
95%
Sampling for SPC is done real time.
To be a member of a Six Sigma project team.

16. Definition of Interaction
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Fractional factorial designs (orthogonal arrays)
Used to create frequency distribution tally sheets
Lean (or JIT).

17. Explain the difference between technical and functional service quality.
Technical quality is the "what" of the service; functional quality is the "how."
Prevention - appraisal - internal failure - external failure.
Hold all input variables constant except one. Observe the response as you vary the single input.
0.9^3 or 72.9%

18. How does Juran define quality?
Fewer good units to sell - increased variable cost/unit.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Fitness for use.
Different types of defects are listed (used for Pareto chart)

19. What are the four categories of costs in Juran's framework?
Prevention - appraisal - internal failure - external failure.
The target number of standard deviations from the mean for specifications.
The gap between what management thinks customers want and the process specifications.
No -- the variation also has to be random and "expected."

20. What does the abbreviation UCL stand for?
A tool that shows where there is waste in a process.
Lower skill requirements - faster - less chance for error.
Upper control limit.
Speed - courtesy - competence - and ease of repair.

21. What is Jidoka?
Controlling quality at the source.
Method developed by Ishikawa to graphically display the causes of any given problem
Blame.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

22. What is the formula for the standard deviation of a proportion?
Is the way in which the failure is manifested.
Shifts - Trends - Repeating patterns - Correlation with known events
=sqrt((p*(1-p)/n)
Method developed by Ishikawa to graphically display the causes of any given problem

23. Define takt time.
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:
If the Response vs. Levels graph if the response lines are not parallel (crossing)
The cycle time required to meet demand.

24. What is a run chart?
Studying firms with the best performance in a particular area.
A time series plot.
Controlling quality at the source.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

25. Defect check sheets
Define - measure - analyze - improve - control.
Different types of defects are listed (used for Pareto chart)
Is the way in which the failure is manifested.
The degree to which a product meets pre-established standards.

26. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Technical quality is the "what" of the service; functional quality is the "how."
5%
To mentor/coach (and sometimes train) black belts.

27. Your production process meets customer specifications. Is your process in control?
Not necessarily.
p-bar - the long-run percent defective.
50%
= yij - y(bar)i --> value minus sum of that treatment (of row)

28. Define features.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
= 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
If the Response vs. Levels graph if the response lines are not parallel (crossing)
The secondary characteristics of a product; "bells and whistles."

29. What happens to control limits on an SPC chart when sample size is increased?
Causes that lead to a particular effect.
Used to create frequency distribution tally sheets
They move closer to the center line.
Lower skill requirements - faster - less chance for error.

30. When is Cpk used?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
To do a capability study for a non-centered process.
No -- only if the process is also capable.
Mistake-proofing.

31. Regression Analysis
A tool that shows where there is waste in a process.
68%
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Consumer risk.

32. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
No -- if it is not the same - it can only be worse!
Lean (or JIT).
Organize ideas into meaningful categories by recognizing their underlying similarity
Fractional factorial designs (orthogonal arrays)

33. Non-random patterns (Run Charts)
The degree to which a product meets pre-established standards.
Pleasing to the senses.
Mean time to replacement.
Shifts - Trends - Repeating patterns - Correlation with known events

34. What is a Pareto chart?
A tool that shows where there is waste in a process.
A descending order-sorted bar chart with a cumulative percentage line.
Failure Modes and Effects Analysis
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

35. Regression
Represents the behavior of a process
The gap between what management thinks customers want and what customers really want.
Observed variation in response is caused by the input
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:

36. Uses of regression - Control
An assertion or conjecture concerning one or more populations
The gap between specifications and how service is performed.
To obtain a certain desirable outcome from the process
The US national quality award.

37. What is poka yoke?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Mistake-proofing.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
10 if Almost impossible to detect

38. Define serviceability.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Outside.
Lower control limit.
Speed - courtesy - competence - and ease of repair.

39. Pareto Analysis
10 for Hazardous without warning 1 for none
The Japanese national quality award.
Controlling quality at the source.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

40. What are two other names for an Ishikawa diagram?
Lower skill requirements - faster - less chance for error.
Fishbone - cause-and-effect diagram.
Shifts - Trends - Repeating patterns - Correlation with known events
10 if Almost impossible to detect

41. What is process capability?
Stratify a particular defect type according to logical criteria
Lower skill requirements - faster - less chance for error.
The ability of a process to consistently meet customer specifications.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

42. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
To do a capability study for a non-centered process.
False - because each machine will have different natural tolerances.
No -- the variation also has to be random and "expected."
The primary operating characteristics of a product.

43. For what is an x-bar chart used?
Initiated before or at design concept finalization
To monitor a process when measurement by variables is used.
p-bar - the long-run percent defective.
Financial - customer - internal process - innovation and learning.

44. Failure effect
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
Is the consequence of the failure.
Inventory = throughput x flow time.
Concluding there has not been an effect/change when there has.

45. In the Service Quality Gap Model - what is Gap 1?
Walter A. Shewhart
A diagram that shows the relationships between activities in a project network.
The gap between what management thinks customers want and what customers really want.
Blame.

46. With Six Sigma capability - how many defects per million opportunities would you see?
Deming.
Prevention and appraisal costs are balanced against internal and external failure.
3.4 (assuming 1.5 sigma shift in the mean)
10 if Almost impossible to detect

47. Failure Mode
Prevention and appraisal costs are balanced against internal and external failure.
Is the way in which the failure is manifested.
Workers - machines - materials.
Concluding there has not been an effect/change when there has.

48. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Actual drawings - layouts - maps - etc which show where a defect occurs
Define - measure - analyze - design - verify.
Variable.
A descending order-sorted bar chart with a cumulative percentage line.

49. Name the structure associated with Quality Function Deployment.
The gap between what customers expect and the service they receive.
The gap between what is promised and what is delivered.
The House of Quality.
Brand image.

50. Define aesthetic quality.
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
The manager in charge of a process being improved in a Six Sigma project.
Attribute
Pleasing to the senses.

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Six Sigma

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