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Six Sigma

Subjects : certifications, six-sigma, business-skills

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Answer 50 questions in 15 minutes.
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1. ANOVA

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2. What is the formula for the standard deviation of a proportion?
Pleasing to the senses.
=sqrt((p*(1-p)/n)
Not necessarily.
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.

3. List two components of external failure.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Define - measure - analyze - design - verify.
Financial - customer - internal process - innovation and learning.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

4. Define benchmarking.
The gap between what is promised and what is delivered.
Studying firms with the best performance in a particular area.
Supplier - input - process - output - 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

5. Define performance quality.
The primary operating characteristics of a product.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Lower skill requirements - faster - less chance for error.
The target number of standard deviations from the mean for specifications.

6. How are LQL and AQL determined in an acceptance sampling plan?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
F_alpha - df(tr) - df (error)
Through producer/consumer negotiation.
It looks to minimize the probability of a failure - or to minimize its effects

7. Manual Test for Nomality
The primary operating characteristics of a product.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
F_alpha - df(tr) - df (error)
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

8. Defect check sheets
Different types of defects are listed (used for Pareto chart)
Conformance to specifications.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
5%

9. What happens to control limits on an SPC chart when sample size is increased?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
They move closer to the center line.
Is what induces the failure
Attribute.

10. What is muda
Waste.
To do a capability study for a non-centered process.
Kaoru Ishikawa.
=sqrt(Σ(x-x-bar)^2)/(n-1))

11. Daniel Test
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
= yij - y(bar)i --> value minus sum of that treatment (of row)
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:
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

12. What is a run chart?
The Japanese national quality award.
A time series plot.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Can't tell without a Range chart.

13. In the Service Quality Gap Model - what is Gap 4?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Shows the temporal flow of activities in a project network.
A diagram that shows the relationships between activities in a project network.
The gap between what is promised and what is delivered.

14. Who first studied randomness in industrial processes
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Walter A. Shewhart
Workers - machines - materials.
Prevention - appraisal - internal failure - external failure.

15. PFMEA
Conformance to specifications.
Before production starts
Upper control limit.
What the value of the dependent variable is when the independent variable is zero.

16. Simple Regression Analysis (one factor regression model)
= 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
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.
Mean time to replacement.
10 if Almost impossible to detect

17. In a Z table - what is Z?
5%
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Sampling for SPC is done real time.
The number of standard deviations some value is from the mean.

18. Cause and Effect Diagrams
Lean is waste reduction - Six Sigma is variation reduction.
The manager in charge of a process being improved in a Six Sigma project.
Method developed by Ishikawa to graphically display the causes of any given problem
Prevention - appraisal - internal failure - external failure.

19. Affinity Diagrams
10 for Hazardous without warning 1 for none
p-bar - the long-run percent defective.
To monitor a process when measurement by attribute is used.
Organize ideas into meaningful categories by recognizing their underlying similarity

20. DFMEA
50%
Initiated before or at design concept finalization
10 if Almost impossible to detect
Attribute

21. For what is a p-chart used?
Through producer/consumer negotiation.
To monitor a process when measurement by attribute is used.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

22. Failure Mode
What the value of the dependent variable is when the independent variable is zero.
Mean time to replacement.
Kaoru Ishikawa.
Is the way in which the failure is manifested.

23. What do you do when a process is out of control?
Because the mean and standard deviation are independent of each other.
Variable.
Look for the assignable cause of non-random variation.
The number of standard deviations some value is from the mean.

24. List two appraisal costs.
Actual drawings - layouts - maps - etc which show where a defect occurs
Walter A. Shewhart
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Pleasing to the senses.

25. List two components of prevention cost.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
A time series plot.
A scatterplot.
Central Limit Theorem

26. Detection Criteria Ranking
10 if Almost impossible to detect
Mean time to replacement.
Represents the behavior of a process
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

27. FMEA
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
Producer risk.
Fitness for use.
Controlling quality at the source.

28. What are the three main categories of assignable cause?
The gap between specifications and how service is performed.
Workers - machines - materials.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
The ratio of outputs to inputs; 1-scrap.

29. What is the center line of an X-bar chart?
X-bar-bar
The degree to which a product meets pre-established standards.
Define - measure - analyze - improve - control.
A tool that shows where there is waste in a process.

30. What size should samples be for attribute SPC?
Large enough to find two of the attribute - on average.
Walter A. Shewhart
Concluding there has been an effect/change when there has not.
Variable.

31. Based on what principal can we use the normal distribution assumptions for SPC?
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.
The gap between what management thinks customers want and the process specifications.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Central Limit Theorem

32. Process check sheets
Used to create frequency distribution tally sheets
Outside.
Causes that lead to a particular effect.
Define - measure - analyze - improve - control.

33. Presence of interaction effect
The cycle time required to meet demand.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
50%
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

34. Non-random patterns (Run Charts)
=sqrt(Σ(x-x-bar)^2)/(n-1))
Shifts - Trends - Repeating patterns - Correlation with known events
Controlling quality at the source.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

35. Who developed the fishbone diagram?
10 for Hazardous without warning 1 for none
Outside.
Variable.
Kaoru Ishikawa.

36. In the Service Quality Gap Model - what is Gap 3?
Variable.
Attribute.
The gap between specifications and how service is performed.
Brand image.

37. Taguchi's experimental designs are of this type.
Fractional factorial designs (orthogonal arrays)
A diagram that shows the relationships between activities in a project network.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
To monitor a process when measurement by variables is used.

38. Test for constant variance
Lean (or JIT).
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.
Pleasing to the senses.
Attribute

39. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Outside.
To manage the Six Sigma project.
Before production starts
Attribute

40. What is Jidoka?
A scatterplot.
To monitor a process when measurement by attribute is used.
Controlling quality at the source.
The number of standard deviations some value is from the mean.

41. Define features.
The secondary characteristics of a product; "bells and whistles."
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
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
To obtain a certain desirable outcome from the process

42. Histogram by Hand
Upper control limit.
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
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).
QFD

43. In a regression - what does the standard error of the estimate tell you?
Lean is waste reduction - Six Sigma is variation reduction.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
QFD
Speed - courtesy - competence - and ease of repair.

44. How does Juran define quality?
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Fitness for use.
Sort - Set in Order - Shine - Standardize - Sustain
No -- the variation also has to be random and "expected."

45. Explain the difference between technical and functional service quality.
Technical quality is the "what" of the service; functional quality is the "how."
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
Shifts - Trends - Repeating patterns - Correlation with known events
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

46. 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?
Not necessarily.
Taguchi
Someone who is consistently against virtually everything.
False - because each machine will have different natural tolerances.

47. Creating a Run Chart
It looks to minimize the probability of a failure - or to minimize its effects
Attribute
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Fishbone - cause-and-effect diagram.

48. What is FMEA?
A tool that shows performance along key dimensions all at once.
Failure Modes and Effects Analysis
The manager in charge of a process being improved in a Six Sigma project.
To do a capability study for a non-centered process.

49. Define yield.
Inventory = throughput x flow time.
Look for the assignable cause of non-random variation.
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
The ratio of outputs to inputs; 1-scrap.

50. Why do you need two control charts for variables SPC?
5%
Because the mean and standard deviation are independent of each other.
F_alpha - df(tr) - df (error)
Causes that lead to a particular effect.

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