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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. List two components of external failure.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Lean (or JIT).
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
The gap between what is promised and what is delivered.

2. In the Service Quality Gap Model - what is Gap 5?
Outside.
F_alpha - df(tr) - df (error)
The gap between what customers expect and the service they receive.
Defects Per Million Opportunities

3. DFMEA
Define - measure - analyze - improve - control.
Initiated before or at design concept finalization
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
Concluding there has not been an effect/change when there has.

4. What size should samples be for attribute SPC?
Studying firms with the best performance in a particular area.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
50%
Large enough to find two of the attribute - on average.

5. If a Cp shows that a process is not capable - should you calculate Cpk?
The degree to which a product meets pre-established standards.
Because the mean and standard deviation are independent of each other.
The Japanese national quality award.
No -- if it is not the same - it can only be worse!

6. What is Type II Error?
Concluding there has not been an effect/change when there has.
Define - measure - analyze - improve - control.
95%
Controlling quality at the source.

7. In the Service Quality Gap Model - what is Gap 1?
To manage the Six Sigma project.
100%
The gap between what management thinks customers want and what customers really want.
The US national quality award.

8. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Outside.
No -- if it is not the same - it can only be worse!
Through producer/consumer negotiation.
Concluding there has been an effect/change when there has not.

9. Your production process meets customer specifications. Is your process in control?
Prevention - appraisal - internal failure - external failure.
The number of standard deviations some value is from the mean.
A diagram that shows the relationships between activities in a project network.
Not necessarily.

10. If a three-stage process has 90% yields at each stage - what is the overall yield?
0.9^3 or 72.9%
Is the consequence of the failure.
Blame.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

11. What is the formula for standard deviation?
To monitor a process when measurement by variables is used.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Financial - customer - internal process - innovation and learning.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

12. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Lean (or JIT).
=sqrt(Σ(x-x-bar)^2)/(n-1))
Conformance to specifications.
Through producer/consumer negotiation.

13. What are the four categories of costs in Juran's framework?
Variable.
100%
Blame.
Prevention - appraisal - internal failure - external failure.

14. Based on what principal can we use the normal distribution assumptions for SPC?
Shifts - Trends - Repeating patterns - Correlation with known events
Rapid improvement process.
Central Limit Theorem
A tool that shows performance along key dimensions all at once.

15. In a regression - what does R-square tell you?
Sort - Set in Order - Shine - Standardize - Sustain
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
A tool that shows the physical flows through a space.
Observed variation in response is caused by the input

16. Define yield.
The ratio of outputs to inputs; 1-scrap.
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).
Fractional factorial designs (orthogonal arrays)
Attribute.

17. What percentage of a normal distribution lies above the mean?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Define - measure - analyze - improve - control.
Is the way in which the failure is manifested.
50%

18. Statistical Hypothesis
Waste.
An assertion or conjecture concerning one or more populations
99.73%
Kaoru Ishikawa.

19. What is the Deming Prize?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
To be a member of a Six Sigma project team.
The Japanese national quality award.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

20. With Six Sigma capability - how many defects per million opportunities would you see?
False - because each machine will have different natural tolerances.
The degree to which a product meets pre-established standards.
p-bar - the long-run percent defective.
3.4 (assuming 1.5 sigma shift in the mean)

21. What is Jidoka?
Controlling quality at the source.
Is what induces the failure
Prevention - appraisal - internal failure - external failure.
Prevention and appraisal costs are balanced against internal and external failure.

22. In a regression - what does the coefficient of the intercept tell you
Taguchi
Consumer risk.
What the value of the dependent variable is when the independent variable is zero.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

23. Process check sheets
Shifts - Trends - Repeating patterns - Correlation with known events
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Used to create frequency distribution tally sheets

24. What is a network diagram?
Failure Modes and Effects Analysis
A diagram that shows the relationships between activities in a project network.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Kaoru Ishikawa.

25. What is muda
Waste.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
No -- only if the process is also capable.
Through producer/consumer negotiation.

26. Presence of interaction effect
Large enough to find two of the attribute - on average.
Can't tell without a Range chart.
Define - measure - analyze - design - verify.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

27. What does the abbreviation LCL stand for?
Lower control limit.
The degree to which a product meets pre-established standards.
A brainstorming tool that shows the connections between ideas.
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

28. PFMEA
Is the consequence of the failure.
A tool that shows where there is waste in a process.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Before production starts

29. What is the role of a black belt?
Studying firms with the best performance in a particular area.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
To manage the Six Sigma project.
Define - measure - analyze - design - verify.

30. What is a CAVE man?
Someone who is consistently against virtually everything.
68%
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
Workers - machines - materials.

31. What are the Five Dimensions of Service Quality?
Can't tell without a Range chart.
10 for Hazardous without warning 1 for none
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Reliability - Assurance - Responsiveness - Tangibles - Empathy

32. What is a Pareto chart?
QFD
A descending order-sorted bar chart with a cumulative percentage line.
Large enough to find two of the attribute - on average.
F_alpha - df(tr) - df (error)

33. Design of Experiments (DOE) approach
The ratio of outputs to inputs; 1-scrap.
To do a capability study for a non-centered process.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Lower control limit.

34. What are the three main categories of assignable cause?
Inventory = throughput x flow time.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Workers - machines - materials.
Lean (or JIT).

35. Define durability.
No -- the variation also has to be random and "expected."
Brand image.
Mean time to replacement.
Organize ideas into meaningful categories by recognizing their underlying similarity

36. What is Value Stream Mapping?
Before production starts
A tool that shows where there is waste in a process.
Waste.
QFD

37. Defect check sheets
X-bar-bar
To mentor/coach (and sometimes train) black belts.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Different types of defects are listed (used for Pareto chart)

38. What quality guru emphasizes management as a system?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Observed variation in response is caused by the input
Deming.
Defects Per Million Opportunities

39. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Prevention - appraisal - internal failure - external failure.
No -- the variation also has to be random and "expected."
X-bar-bar
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

40. In a regression - what does the standard error of the estimate tell you?
Waste.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Inventory = throughput x flow time.
Shifts - Trends - Repeating patterns - Correlation with known events

41. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
Kaoru Ishikawa.
Defects Per Million Opportunities
F_alpha - df(tr) - df (error)
100%

42. What is a spaghetti diagram?
No -- only if the process is also capable.
Lower skill requirements - faster - less chance for error.
A tool that shows the physical flows through a space.
The House of Quality.

43. FMEA
Walter A. Shewhart
It looks to minimize the probability of a failure - or to minimize its effects
What the value of the dependent variable is when the independent variable is zero.
Observed variation in response is caused by the input

44. To what does the Six in Six Sigma relate?
100%
The target number of standard deviations from the mean for 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
Define - measure - analyze - improve - control.

45. What is poka yoke?
QFD
Mistake-proofing.
A diagram that shows the relationships between activities in a project network.
100%

46. Affinity Diagrams
A random variable that summarizes the information from the sample(s).
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Shifts - Trends - Repeating patterns - Correlation with known events
Organize ideas into meaningful categories by recognizing their underlying similarity

47. What are two other names for an Ishikawa diagram?
Fishbone - cause-and-effect diagram.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The gap between what is promised and what is delivered.

48. Regression Analysis
Is the consequence of the failure.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
To mentor/coach (and sometimes train) black belts.
Blame.

49. A process is operating "in control." Does this mean the customer's requirements are met?
Look for the assignable cause of non-random variation.
No -- only if the process is also capable.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Variable.

50. What is Little's Law?
To monitor a process when measurement by attribute is used.
Inventory = throughput x flow time.
0.9^3 or 72.9%
Studying firms with the best performance in a particular area.

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Six Sigma

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