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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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1. Affinity Diagrams
To mentor/coach (and sometimes train) black belts.
Lower skill requirements - faster - less chance for error.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
A tool that shows the physical flows through a space.

2. What is Type 1 Error?
Someone who is consistently against virtually everything.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
=sqrt((p*(1-p)/n)
Concluding there has been an effect/change when there has not.

3. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Pleasing to the senses.
Prevention - appraisal - internal failure - external failure.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
5%

4. Taguchi's experimental designs are of this type.
p-bar - the long-run percent defective.
Different types of defects are listed (used for Pareto chart)
Fractional factorial designs (orthogonal arrays)
Waste.

5. What do you do when a process is out of control?
100%
Look for the assignable cause of non-random variation.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
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).

6. Risk Priority Number RPN
What the value of the dependent variable is when the independent variable is zero.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Variable.
Walter A. Shewhart

7. Definition of Interaction
To obtain a certain desirable outcome from the process
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The gap between what management thinks customers want and the process specifications.
Before production starts

8. List two components of prevention cost.
Deming.
Fractional factorial designs (orthogonal arrays)
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
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

9. Disadvantages of DOE

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10. List two components of internal failure.
Define - measure - analyze - design - verify.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Someone who is consistently against virtually everything.
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.

11. What is a histogram?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Fitness for use.
5%

12. Your production process meets customer specifications. Is your process in control?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Because the mean and standard deviation are independent of each other.
Not necessarily.
Represents the behavior of a process

13. Define conformance quality.
The degree to which a product meets pre-established standards.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Walter A. Shewhart
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

14. TWO-DIMENTIONAL SCATTER PLOT
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
To obtain a certain desirable outcome from the process
Attribute.

15. What are the 5 Ss?
Sort - Set in Order - Shine - Standardize - Sustain
Fishbone - cause-and-effect diagram.
The primary operating characteristics of a product.
0.9^3 or 72.9%

16. Define takt time.
The cycle time required to meet demand.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

17. If a Cp shows that a process is not capable - should you calculate Cpk?
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
No -- if it is not the same - it can only be worse!
Defects Per Million Opportunities
The gap between what management thinks customers want and what customers really want.

18. What are the three main categories of assignable cause?
Mistake-proofing.
Workers - machines - materials.
Fishbone - cause-and-effect diagram.
Before production starts

19. The data points on an SPC p-chart of defective percent plot below the mean. Is this good or bad?

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20. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Supplier - input - process - output - customer.
99.73%
Observed variation in response is caused by the input
Different types of defects are listed (used for Pareto chart)

21. What is written on the "spines" of a fishbone diagram?
Is the way in which the failure is manifested.
Prevention and appraisal costs are balanced against internal and external failure.
Deming.
Causes that lead to a particular effect.

22. In the Service Quality Gap Model - what is Gap 4?
Used to create frequency distribution tally sheets
The gap between what customers expect and the service they receive.
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).
The gap between what is promised and what is delivered.

23. In the Service Quality Gap Model - what is Gap 2?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
The gap between what management thinks customers want and the process specifications.
What the value of the dependent variable is when the independent variable is zero.

24. Presence of interaction effect
Look for the assignable cause of non-random variation.
Is the way in which the failure is manifested.
The ability of a process to consistently meet customer specifications.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

25. Who is a process owner?
Assigns scores to weighted criteria for each project under consideration.
Controlling quality at the source.
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
The manager in charge of a process being improved in a Six Sigma project.

26. In the Service Quality Gap Model - what is Gap 5?
Hold all input variables constant except one. Observe the response as you vary the single input.
The gap between what customers expect and the service they receive.
Failure Modes and Effects Analysis
Large enough to find two of the attribute - on average.

27. 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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28. ANOVA

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29. Creating a Run Chart
Outside.
Concluding there has been an effect/change when there has not.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The gap between specifications and how service is performed.

30. The Test Statistic (TS)
99.73%
Actual drawings - layouts - maps - etc which show where a defect occurs
A random variable that summarizes the information from the sample(s).
The primary operating characteristics of a product.

31. DFMEA
Initiated before or at design concept finalization
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Because the mean and standard deviation are independent of each other.
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).

32. What quality guru emphasizes management as a system?
The House of Quality.
Look for the assignable cause of non-random variation.
A tool that shows performance along key dimensions all at once.
Deming.

33. Defect location check sheets
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Actual drawings - layouts - maps - etc which show where a defect occurs
A brainstorming tool that shows the connections between ideas.
The US national quality award.

34. When yields decrease - what are the two effects on contribution?
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
Fewer good units to sell - increased variable cost/unit.
50%
The US national quality award.

35. Who developed the fishbone diagram?
It looks to minimize the probability of a failure - or to minimize its effects
Can't tell without a Range chart.
Different types of defects are listed (used for Pareto chart)
Kaoru Ishikawa.

36. Process occurance ranking
0.9^3 or 72.9%
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
A scatterplot.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

37. What is process capability?
A brainstorming tool that shows the connections between ideas.
Someone who is consistently against virtually everything.
A time series plot.
The ability of a process to consistently meet customer specifications.

38. If you have calculated a Cpk - should you also calculate a Cp?
Technical quality is the "what" of the service; functional quality is the "how."
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
No -- the variation also has to be random and "expected."
Supplier - input - process - output - customer.

39. What is the Baldrige Award?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Rapid improvement process.
Scrap - rework - retest - downtime - yield losses - disposition costs.
The US national quality award.

40. What does the abbreviation UCL stand for?
The gap between what customers expect and the service they receive.
0.9^3 or 72.9%
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Upper control limit.

41. FMEA
A time series plot.
Mean time to failure.
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
50%

42. In a regression - what does the coefficient of the intercept tell you
The Japanese national quality award.
What the value of the dependent variable is when the independent variable is zero.
Mistake-proofing.
Kaoru Ishikawa.

43. Define product reliability.
Hold all input variables constant except one. Observe the response as you vary the single input.
Mean time to failure.
A time series plot.
p-bar - the long-run percent defective.

44. F value
Initiated before or at design concept finalization
F_alpha - df(tr) - df (error)
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

45. In a regression - what does the p value of F tell you?
What the value of the dependent variable is when the independent variable is zero.
95%
A tool that shows where there is waste in a 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).

46. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Lower skill requirements - faster - less chance for error.
A tool that shows where there is waste in a process.
Workers - machines - materials.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

47. Define features.
The secondary characteristics of a product; "bells and whistles."
Assigns scores to weighted criteria for each project under consideration.
Prevention and appraisal costs are balanced against internal and external failure.
Financial - customer - internal process - innovation and learning.

48. DOE
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Observed variation in response is caused by the input
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Conformance to specifications.

49. Uses of regression - Control
Prevention - appraisal - internal failure - external failure.
To obtain a certain desirable outcome from the process
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

50. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
The gap between what management thinks customers want and what customers really want.
Scrap - rework - retest - downtime - yield losses - disposition costs.
= 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
Lean (or JIT).

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