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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. How does Juran define quality?
Attribute.
Fitness for use.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
A diagram that shows the relationships between activities in a project network.

2. If you can only collect categorical data - what type of SPC charting can you do?
Deming.
Workers - machines - materials.
To monitor a process when measurement by variables is used.
Attribute.

3. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
The House of Quality.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
A scatterplot.
95%

4. Define aesthetic quality.
The Japanese national quality award.
Pleasing to the senses.
Not necessarily.
Mistake-proofing.

5. Effect ranking (Severity of the Defect)
95%
10 for Hazardous without warning 1 for none
X-bar-bar
To obtain a certain desirable outcome from the process

6. What is written on the "spines" of a fishbone diagram?
A brainstorming tool that shows the connections between ideas.
A time series plot.
The gap between what is promised and what is delivered.
Causes that lead to a particular effect.

7. What is a dashboard?
10 if Almost impossible to detect
Inventory = throughput x flow time.
A tool that shows performance along key dimensions all at once.
Workers - machines - materials.

8. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Producer risk.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
To obtain a certain desirable outcome from the process
Lean (or JIT).

9. FMEA
Supplier - input - process - output - customer.
Define - measure - analyze - improve - control.
Concluding there has not been an effect/change when there has.
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

10. Process check sheets
Mean time to replacement.
Used to create frequency distribution tally sheets
Shifts - Trends - Repeating patterns - Correlation with known events
Attribute

11. Define durability.
They move closer to the center line.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Mean time to replacement.
Waste.

12. What does DMAIC stand for?
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.
Producer risk.
Define - measure - analyze - improve - control.
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).

13. In the Service Quality Gap Model - what is Gap 5?
The Japanese national quality award.
Conformance to specifications.
The gap between what customers expect and the service they receive.
10 if Almost impossible to detect

14. What is CTQ?
Fitness for use.
Critical to quality.
The gap between what management thinks customers want and the process specifications.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

15. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
X-bar-bar
Conformance to specifications.
An assertion or conjecture concerning one or more populations
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

16. What is an affinity diagram?
No -- only if the process is also capable.
Technical quality is the "what" of the service; functional quality is the "how."
A brainstorming tool that shows the connections between ideas.
Lean is waste reduction - Six Sigma is variation reduction.

17. Test for constant variance
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.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Not necessarily.
3.4 (assuming 1.5 sigma shift in the mean)

18. What does a project prioritization matrix do?
Assigns scores to weighted criteria for each project under consideration.
Define - measure - analyze - improve - control.
The Japanese national quality award.
50%

19. What is DMADV?
Linearity - normality - homoscedasticity - independence.
Concluding there has not been an effect/change when there has.
Define - measure - analyze - design - verify.
Controlling quality at the source.

20. Explain the difference between technical and functional service quality.
X-bar-bar
Technical quality is the "what" of the service; functional quality is the "how."
Attribute
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

21. List two appraisal costs.
Pleasing to the senses.
Lean (or JIT).
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

22. What is the Deming Prize?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
To do a capability study for a non-centered process.
The Japanese national quality award.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

23. Histogram by Hand
Mistake-proofing.
Critical to 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
If the Response vs. Levels graph if the response lines are not parallel (crossing)

24. Define serviceability.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
No -- if it is not the same - it can only be worse!
Speed - courtesy - competence - and ease of repair.
=sqrt(Σ(x-x-bar)^2)/(n-1))

25. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
p-bar - the long-run percent defective.
Pleasing to the senses.
A tool that shows where there is waste in a process.
No -- the variation also has to be random and "expected."

26. Failure effect
The gap between what is promised and what is delivered.
The number of standard deviations some value is from the mean.
Is the consequence of the failure.
Rapid improvement process.

27. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
A descending order-sorted bar chart with a cumulative percentage line.
Consumer risk.
Variable.

28. Defect check sheets
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Central Limit Theorem
Different types of defects are listed (used for Pareto chart)
Variable.

29. DFMEA
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
Initiated before or at design concept finalization
The primary operating characteristics of a product.
Waste.

30. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Concluding there has not been an effect/change when there has.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
68%
10 for Hazardous without warning 1 for none

31. If a Cp shows that a process is not capable - should you calculate Cpk?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
No -- if it is not the same - it can only be worse!
They move closer to the center line.
The House of Quality.

32. What is muda
Scrap - rework - retest - downtime - yield losses - disposition costs.
95%
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.
Waste.

33. What is process capability?
QFD
Critical to quality.
The US national quality award.
The ability of a process to consistently meet customer specifications.

34. List Garvin's eight dimensions of product quality.
Supplier - input - process - output - customer.
10 for Hazardous without warning 1 for none
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

35. Uses of regression - Control
Inventory = throughput x flow time.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
To obtain a certain desirable outcome from the process
3.4 (assuming 1.5 sigma shift in the mean)

36. F value
= yij - y(bar)i --> value minus sum of that treatment (of row)
F_alpha - df(tr) - df (error)
Initiated before or at design concept finalization
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:

37. Taguchi's experimental designs are of this type.
Stratify a particular defect type according to logical criteria
Kaoru Ishikawa.
Fractional factorial designs (orthogonal arrays)
They move closer to the center line.

38. In a regression - what does R-square tell you?
Concluding there has been an effect/change when there has not.
A tool that shows the physical flows through a space.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Prevention - appraisal - internal failure - external failure.

39. Define performance quality.
The primary operating characteristics of a product.
10 for Hazardous without warning 1 for none
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
A tool that shows where there is waste in a process.

40. 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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41. Which type of SPC measurement is more precise - variable or attribute?
The gap between what management thinks customers want and the process specifications.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Variable.
50%

42. Uses of regression
Brand image.
= 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
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Different types of defects are listed (used for Pareto chart)

43. In the Service Quality Gap Model - what is Gap 2?
Brand image.
= 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
Is what induces the failure
The gap between what management thinks customers want and the process specifications.

44. Affinity Diagrams
The gap between what customers expect and the service they receive.
To mentor/coach (and sometimes train) black belts.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

45. Disadvantages of DOE

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46. What is Value Stream Mapping?
Define - measure - analyze - improve - control.
A tool that shows where there is waste in a process.
The gap between what management thinks customers want and what customers really want.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

47. Risk Priority Number RPN
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Fractional factorial designs (orthogonal arrays)
Deming.
Used to create frequency distribution tally sheets

48. FMEA
No -- only if the process is also capable.
Kaoru Ishikawa.
It looks to minimize the probability of a failure - or to minimize its effects
68%

49. Based on what principal can we use the normal distribution assumptions for SPC?
Blame.
Concluding there has not been an effect/change when there has.
95%
Central Limit Theorem

50. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
Fewer good units to sell - increased variable cost/unit.
= 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
Stratify a particular defect type according to logical criteria

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