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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. What is an affinity diagram?
Consumer risk.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
p-bar - the long-run percent defective.
A brainstorming tool that shows the connections between ideas.

2. Who first studied randomness in industrial processes
Through producer/consumer negotiation.
10 for Hazardous without warning 1 for none
Walter A. Shewhart
The gap between what customers expect and the service they receive.

3. Presence of interaction effect
Used to create frequency distribution tally sheets
The gap between what customers expect and the service they receive.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Outside.

4. How does Juran define quality?
No -- only if the process is also capable.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
3.4 (assuming 1.5 sigma shift in the mean)
Fitness for use.

5. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
The number of standard deviations some value is from the mean.
QFD
Through producer/consumer negotiation.
Conformance to specifications.

6. One factor at a time (OFAT)
Brand image.
Hold all input variables constant except one. Observe the response as you vary the single input.
Method developed by Ishikawa to graphically display the causes of any given problem
Blame.

7. What does Crosby say about benchmarking?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
p-bar - the long-run percent defective.
=sqrt((p*(1-p)/n)
= yij - y(bar)i --> value minus sum of that treatment (of row)

8. Defect location check sheets
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Actual drawings - layouts - maps - etc which show where a defect occurs
Controlling quality at the source.
The degree to which a product meets pre-established standards.

9. Which type of SPC measurement is more precise - variable or attribute?
Represents the behavior of a process
Actual drawings - layouts - maps - etc which show where a defect occurs
Variable.
A brainstorming tool that shows the connections between ideas.

10. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
99.73%
A time series plot.
Look for the assignable cause of non-random variation.
Concluding there has not been an effect/change when there has.

11. What is the role of a green belt?
The degree to which a product meets pre-established standards.
Pleasing to the senses.
To be a member of a Six Sigma project team.
A scatterplot.

12. List Garvin's eight dimensions of product quality.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Central Limit Theorem
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

13. One factor at a time (OFAT)
Observed variation in response is caused by the input
A random variable that summarizes the information from the sample(s).
Kaoru Ishikawa.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

14. What does the abbreviation LCL stand for?
Lower control limit.
A tool that shows the physical flows through a space.
The US national quality award.
= yij - y(bar)i --> value minus sum of that treatment (of row)

15. Stratified defect check sheets
The primary operating characteristics of a product.
10 for Hazardous without warning 1 for none
To mentor/coach (and sometimes train) black belts.
Stratify a particular defect type according to logical criteria

16. If a three-stage process has 90% yields at each stage - what is the overall yield?
Pleasing to the senses.
Rapid improvement process.
Assigns scores to weighted criteria for each project under consideration.
0.9^3 or 72.9%

17. What are two other names for an Ishikawa diagram?
To manage the Six Sigma project.
Define - measure - analyze - design - verify.
Before production starts
Fishbone - cause-and-effect diagram.

18. FMEA
A tool that shows the physical flows through a space.
Someone who is consistently against virtually everything.
The House of Quality.
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

19. What is DPMO?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
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
Defects Per Million Opportunities
A tool that shows where there is waste in a process.

20. What is CTQ?
Critical to quality.
No -- the variation also has to be random and "expected."
The gap between what is promised and what is delivered.
The US national quality award.

21. A process is operating "in control." Does this mean the customer's requirements are met?
Stratify a particular defect type according to logical criteria
Not necessarily.
No -- only if the process is also capable.
The target number of standard deviations from the mean for specifications.

22. If you can only collect categorical data - what type of SPC charting can you do?
The gap between what is promised and what is delivered.
Attribute.
A random variable that summarizes the information from the sample(s).
Hold all input variables constant except one. Observe the response as you vary the single input.

23. Define aesthetic quality.
Is what induces the failure
Pleasing to the senses.
The primary operating characteristics of a product.
The gap between what management thinks customers want and the process specifications.

24. Uses of regression - Control
Observed variation in response is caused by the input
Lean (or JIT).
Stratify a particular defect type according to logical criteria
To obtain a certain desirable outcome from the process

25. What is a spaghetti diagram?
Variable.
A tool that shows the physical flows through a space.
Walter A. Shewhart
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

26. Define perceived quality (Garvin's framework).
It's good -- but it's still out of control!
100%
Fractional factorial designs (orthogonal arrays)
Brand image.

27. Failure effect
QFD
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Is the consequence of the failure.
Define - measure - analyze - design - verify.

28. In Juran's Cost of Quality model - which categories of costs balance which other categories?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Prevention and appraisal costs are balanced against internal and external failure.
Look for the assignable cause of non-random variation.

29. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Sampling for SPC is done real time.
Lower control limit.
Concluding there has not been an effect/change when there has.
It's good -- but it's still out of control!

30. What is muda
Through producer/consumer negotiation.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Before production starts
Waste.

31. What is Type II Error?
Concluding there has not been an effect/change when there has.
Through producer/consumer negotiation.
Define - measure - analyze - improve - control.
Is the way in which the failure is manifested.

32. What is FMEA?
Represents the behavior of a process
Mean time to failure.
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
Failure Modes and Effects Analysis

33. F value
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
An assertion or conjecture concerning one or more populations
F_alpha - df(tr) - df (error)
Lower control limit.

34. ANOVA

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35. What quality tool formally incorporates the voice of the customer?
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
The gap between specifications and how service is performed.
QFD
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

36. 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.
Prevention - appraisal - internal failure - external failure.
The cycle time required to meet demand.
Is the way in which the failure is manifested.

37. Design of Experiments (DOE) approach
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The ratio of outputs to inputs; 1-scrap.
50%

38. In the Service Quality Gap Model - what is Gap 4?
Variable.
The gap between what is promised and what is delivered.
A random variable that summarizes the information from the sample(s).
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

39. Non-random patterns (Run Charts)
Concluding there has been an effect/change when there has not.
Pleasing to the senses.
A tool that shows the physical flows through a space.
Shifts - Trends - Repeating patterns - Correlation with known events

40. The Test Statistic (TS)
Mistake-proofing.
10 for Hazardous without warning 1 for none
A random variable that summarizes the information from the sample(s).
Walter A. Shewhart

41. Define product reliability.
Fishbone - cause-and-effect diagram.
Supplier - input - process - output - customer.
Mean time to failure.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

42. 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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43. Process check sheets
To obtain a certain desirable outcome from the process
Used to create frequency distribution tally sheets
Prevention and appraisal costs are balanced against internal and external failure.
Fewer good units to sell - increased variable cost/unit.

44. What type of risk is associated with Type 1 Error?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Shifts - Trends - Repeating patterns - Correlation with known events
Method developed by Ishikawa to graphically display the causes of any given problem
Producer risk.

45. What size should samples be for attribute SPC?
Concluding there has not been an effect/change when there has.
Prevention - appraisal - internal failure - external failure.
Large enough to find two of the attribute - on average.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

46. What is the Baldrige Award?
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:
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Scrap - rework - retest - downtime - yield losses - disposition costs.
The US national quality award.

47. TWO-DIMENTIONAL SCATTER PLOT
Prevention - appraisal - internal failure - external failure.
0.9^3 or 72.9%
A scatterplot.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

48. What are the four regression assumptions?
Defects Per Million Opportunities
A brainstorming tool that shows the connections between ideas.
The ratio of outputs to inputs; 1-scrap.
Linearity - normality - homoscedasticity - independence.

49. What percentage of a normal distribution lies above the mean?
Lean (or JIT).
99.73%
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
50%

50. What is process capability?
To mentor/coach (and sometimes train) black belts.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
The ability of a process to consistently meet customer specifications.
No -- the variation also has to be random and "expected."

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