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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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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 do you do when a process is out of control?
The number of standard deviations some value is from the mean.
Look for the assignable cause of non-random variation.
Define - measure - analyze - improve - control.
Can't tell without a Range chart.

2. What is an affinity diagram?
A brainstorming tool that shows the connections between ideas.
The Japanese national quality award.
Observed variation in response is caused by the input
Critical to quality.

3. What is a spaghetti diagram?
Lean (or JIT).
Lean is waste reduction - Six Sigma is variation reduction.
A tool that shows the physical flows through a space.
Method developed by Ishikawa to graphically display the causes of any given problem

4. Who first studied randomness in industrial processes
Walter A. Shewhart
10 if Almost impossible to detect
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
To monitor a process when measurement by variables is used.

5. The Test Statistic (TS)
Sampling for SPC is done real time.
Mean time to replacement.
A random variable that summarizes the information from the sample(s).
No -- only if the process is also capable.

6. Who is a process owner?
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
The manager in charge of a process being improved in a Six Sigma project.
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:
Is the consequence of the failure.

7. One factor at a time (OFAT)
A tool that shows performance along key dimensions all at once.
Hold all input variables constant except one. Observe the response as you vary the single input.
The manager in charge of a process being improved in a Six Sigma project.
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).

8. Your production process meets customer specifications. Is your process in control?
Initiated before or at design concept finalization
To do a capability study for a non-centered process.
An assertion or conjecture concerning one or more populations
Not necessarily.

9. Define serviceability.
A diagram that shows the relationships between activities in a project network.
Lower control limit.
Speed - courtesy - competence - and ease of repair.
Waste.

10. Regression
Represents the behavior of a process
Organize ideas into meaningful categories by recognizing their underlying similarity
The gap between specifications and how service is performed.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

11. What are the 5 Ss?
Variable.
95%
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
Sort - Set in Order - Shine - Standardize - Sustain

12. To what does the Six in Six Sigma relate?
The Japanese national quality award.
The target number of standard deviations from the mean for specifications.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
No -- only if the process is also capable.

13. Stratified defect check sheets
Stratify a particular defect type according to logical criteria
To do a capability study for a non-centered process.
Sort - Set in Order - Shine - Standardize - Sustain
Look for the assignable cause of non-random variation.

14. Process occurance ranking
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
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
To mentor/coach (and sometimes train) black belts.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

15. Effect ranking (Severity of the Defect)
Is the consequence of the failure.
10 for Hazardous without warning 1 for none
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
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).

16. List two components of prevention cost.
Mean time to replacement.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Consumer risk.
To manage the Six Sigma project.

17. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
95%
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Is the consequence of the failure.
To obtain a certain desirable outcome from the process

18. Pareto Analysis
What the value of the dependent variable is when the independent variable is zero.
Organize ideas into meaningful categories by recognizing their underlying similarity
Waste.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

19. What is muda
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
Is the consequence of the failure.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Waste.

20. Based on what principal can we use the normal distribution assumptions for SPC?
Mean time to failure.
To do a capability study for a non-centered process.
Central Limit Theorem
The degree to which a product meets pre-established standards.

21. In a Z table - what is Z?
The number of standard deviations some value is from the mean.
The gap between what management thinks customers want and the process specifications.
Large enough to find two of the attribute - on average.
3.4 (assuming 1.5 sigma shift in the mean)

22. Failure cause
Deming.
Initiated before or at design concept finalization
Is what induces the failure
A time series plot.

23. What are the four perspectives of the Balanced Scorecard?
The primary operating characteristics of a product.
0.9^3 or 72.9%
Before production starts
Financial - customer - internal process - innovation and learning.

24. What is Little's Law?
3.4 (assuming 1.5 sigma shift in the mean)
Inventory = throughput x flow time.
The secondary characteristics of a product; "bells and whistles."
Can't tell without a Range chart.

25. What is the difference between the way sampling is done for SPC and for acceptance sampling?
QFD
Actual drawings - layouts - maps - etc which show where a defect occurs
Sampling for SPC is done real time.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

26. Detection Criteria Ranking
10 if Almost impossible to detect
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).
Defects Per Million Opportunities
The gap between what management thinks customers want and what customers really want.

27. Define performance quality.
To do a capability study for a non-centered process.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The primary operating characteristics of a product.
Conformance to specifications.

28. What does the abbreviation LCL stand for?
Critical to quality.
0.9^3 or 72.9%
Someone who is consistently against virtually everything.
Lower control limit.

29. In the Service Quality Gap Model - what is Gap 1?
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
The gap between what management thinks customers want and what customers really want.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

30. If you can only collect categorical data - what type of SPC charting can you do?
Attribute.
Defects Per Million Opportunities
Stratify a particular defect type according to logical criteria
100%

31. What does the abbreviation UCL stand for?
Can't tell without a Range chart.
Upper control limit.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
68%

32. In the Service Quality Gap Model - what is Gap 3?
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
The gap between specifications and how service is performed.
Stratify a particular defect type according to logical criteria
Can't tell without a Range chart.

33. In the Service Quality Gap Model - what is Gap 4?
0.9^3 or 72.9%
The gap between what is promised and what is delivered.
A time series plot.
The ratio of outputs to inputs; 1-scrap.

34. FMEA
It looks to minimize the probability of a failure - or to minimize its effects
A tool that shows the physical flows through a space.
Variable.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

35. What size should samples be for attribute SPC?
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).
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Large enough to find two of the attribute - on average.

36. What does a project prioritization matrix do?
Supplier - input - process - output - customer.
Assigns scores to weighted criteria for each project under consideration.
Not necessarily.
Scrap - rework - retest - downtime - yield losses - disposition costs.

37. In a regression - what does the standard error of the estimate tell you?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Conformance to specifications.
Is what induces the failure
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.

38. What is process capability?
Define - measure - analyze - design - verify.
To mentor/coach (and sometimes train) black belts.
The ability of a process to consistently meet customer specifications.
Deming.

39. What are two other names for an Ishikawa diagram?
A descending order-sorted bar chart with a cumulative percentage line.
Is the consequence of the failure.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Fishbone - cause-and-effect diagram.

40. What is the role of a master black belt?
Attribute.
To mentor/coach (and sometimes train) black belts.
A tool that shows where there is waste in a process.
Conformance to specifications.

41. FMEA
The target number of standard deviations from the mean for specifications.
p-bar - the long-run percent defective.
Organize ideas into meaningful categories by recognizing their underlying similarity
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

42. In a regression - what does the p value of F tell you?
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.
Actual drawings - layouts - maps - etc which show where a defect occurs
To mentor/coach (and sometimes train) black belts.

43. Define conformance quality.
= 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
Causes that lead to a particular effect.
To be a member of a Six Sigma project team.
The degree to which a product meets pre-established standards.

44. Failure effect
A tool that shows performance along key dimensions all at once.
100%
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Is the consequence of the failure.

45. Complete this quality phrase: 'Fix the process - not the _____.'
Kaoru Ishikawa.
Rapid improvement process.
Blame.
Is the way in which the failure is manifested.

46. What is a dashboard?
The gap between specifications and how service is performed.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
No -- if it is not the same - it can only be worse!
A tool that shows performance along key dimensions all at once.

47. Cause and Effect Diagrams
Define - measure - analyze - design - verify.
Method developed by Ishikawa to graphically display the causes of any given problem
Sampling for SPC is done real time.
QFD

48. Define takt time.
Taguchi
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
99.73%
The cycle time required to meet demand.

49. What is a Gage R&R?
The gap between what customers expect and the service they receive.
Consumer risk.
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).
Can't tell without a Range chart.

50. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
The gap between what customers expect and the service they receive.
No -- the variation also has to be random and "expected."
Shifts - Trends - Repeating patterns - Correlation with known events
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

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