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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 is muda
=sqrt((p*(1-p)/n)
Shifts - Trends - Repeating patterns - Correlation with known events
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).
Waste.

2. Definition of Interaction
p-bar - the long-run percent defective.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Causes that lead to a particular effect.
=sqrt(Σ(x-x-bar)^2)/(n-1))

3. In the Service Quality Gap Model - what is Gap 2?
The gap between what management thinks customers want and the process specifications.
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
Sort - Set in Order - Shine - Standardize - Sustain
Define - measure - analyze - design - verify.

4. 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.
A tool that shows performance along key dimensions all at once.
Financial - customer - internal process - innovation and learning.
It's good -- but it's still out of control!

5. In a regression - what does the p value of F tell you?
10 for Hazardous without warning 1 for none
Speed - courtesy - competence - and ease of repair.
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).
Taguchi

6. What is a network diagram?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
False - because each machine will have different natural tolerances.
Shows the temporal flow of activities in a project network.
A diagram that shows the relationships between activities in a project network.

7. Define product reliability.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The number of standard deviations some value is from the mean.
100%
Mean time to failure.

8. Effect ranking (Severity of the Defect)
A diagram that shows the relationships between activities in a project network.
3.4 (assuming 1.5 sigma shift in the mean)
10 for Hazardous without warning 1 for none
QFD

9. Disadvantages of DOE

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10. Failure Mode
To be a member of a Six Sigma project team.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Is the way in which the failure is manifested.
95%

11. 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
Define - measure - analyze - improve - control.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
No -- the variation also has to be random and "expected."

12. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Can't tell without a Range chart.
Kaoru Ishikawa.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Lower skill requirements - faster - less chance for error.

13. DOE
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
Controlling quality at the source.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
68%

14. F value
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
F_alpha - df(tr) - df (error)
The degree to which a product meets pre-established standards.
Prevention - appraisal - internal failure - external failure.

15. Define features.
3.4 (assuming 1.5 sigma shift in the mean)
Before production starts
Reliability - Assurance - Responsiveness - Tangibles - Empathy
The secondary characteristics of a product; "bells and whistles."

16. What is a Gage R&R?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
It's good -- but it's still out of control!
=sqrt(Σ(x-x-bar)^2)/(n-1))
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).

17. Define takt time.
Upper control limit.
Prevention and appraisal costs are balanced against internal and external failure.
The primary operating characteristics of a product.
The cycle time required to meet demand.

18. List Garvin's eight dimensions of product quality.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
10 if Almost impossible to detect
To monitor a process when measurement by variables is used.
The House of Quality.

19. How are LQL and AQL determined in an acceptance sampling plan?
Outside.
Through producer/consumer negotiation.
0.9^3 or 72.9%
Shifts - Trends - Repeating patterns - Correlation with known events

20. What is Kaizen?
The target number of standard deviations from the mean for specifications.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Rapid improvement process.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

21. Failure effect
Is the consequence of the failure.
Actual drawings - layouts - maps - etc which show where a defect occurs
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
Producer risk.

22. Define yield.
The US national quality award.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The gap between what is promised and what is delivered.
The ratio of outputs to inputs; 1-scrap.

23. Process check sheets
A tool that shows the physical flows through a space.
Upper control limit.
Fitness for use.
Used to create frequency distribution tally sheets

24. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Producer risk.
99.73%
A scatterplot.
The Japanese national quality award.

25. In the Service Quality Gap Model - what is Gap 5?
The degree to which a product meets pre-established standards.
The gap between what customers expect and the service they receive.
= 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
Workers - machines - materials.

26. Which type of SPC measurement is more precise - variable or attribute?
Variable.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Method developed by Ishikawa to graphically display the causes of any given problem
Hold all input variables constant except one. Observe the response as you vary the single input.

27. Risk Priority Number RPN
Attribute
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
95%

28. In the Service Quality Gap Model - what is Gap 3?
Hold all input variables constant except one. Observe the response as you vary the single input.
The gap between specifications and how service is performed.
Someone who is consistently against virtually everything.
Conformance to specifications.

29. A process is operating "in control." Does this mean the customer's requirements are met?
Brand image.
No -- only if the process is also capable.
Causes that lead to a particular effect.
Define - measure - analyze - design - verify.

30. Residual
False - because each machine will have different natural tolerances.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The secondary characteristics of a product; "bells and whistles."
Attribute

31. 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.
Someone who is consistently against virtually everything.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
95%

32. What is the 5S model?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Brand image.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Studying firms with the best performance in a particular area.

33. What percentage of a normal distribution lies above the mean?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
50%
Critical to quality.
Inventory = throughput x flow time.

34. Taguchi's experimental designs are of this type.
Fractional factorial designs (orthogonal arrays)
Sort - Set in Order - Shine - Standardize - Sustain
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
100%

35. What is the formula for the standard deviation of a proportion?
Before production starts
=sqrt((p*(1-p)/n)
Deming.
68%

36. Histogram by Hand
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
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:
Before production starts
Large enough to find two of the attribute - on average.

37. Does it ever make sense to accept a job when a process is incapable?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Waste.
Someone who is consistently against virtually everything.
False - because each machine will have different natural tolerances.

38. Regression
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
To mentor/coach (and sometimes train) black belts.
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
Represents the behavior of a process

39. What does DMAIC stand for?
Define - measure - analyze - improve - control.
Pleasing to the senses.
A tool that shows performance along key dimensions all at once.
A brainstorming tool that shows the connections between ideas.

40. What type of risk is associated with Type II Error?
Attribute.
Consumer risk.
95%
Mean time to replacement.

41. Manual Test for Nomality
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
No -- the variation also has to be random and "expected."
Speed - courtesy - competence - and ease of repair.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

42. Affinity Diagrams
Speed - courtesy - competence - and ease of repair.
99.73%
Method developed by Ishikawa to graphically display the causes of any given problem
Organize ideas into meaningful categories by recognizing their underlying similarity

43. In a Z table - what is Z?
=sqrt(Σ(x-x-bar)^2)/(n-1))
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:
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
The number of standard deviations some value is from the mean.

44. What do you do when a process is out of control?
Look for the assignable cause of non-random variation.
A tool that shows the physical flows through a space.
Workers - machines - materials.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

45. Stratified defect check sheets
X-bar-bar
Stratify a particular defect type according to logical criteria
QFD
= 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

46. One factor at a time (OFAT)
They move closer to the center line.
Organize ideas into meaningful categories by recognizing their underlying similarity
A scatterplot.
Hold all input variables constant except one. Observe the response as you vary the single input.

47. What does SIPOC stand for?
Concluding there has been an effect/change when there has not.
What the value of the dependent variable is when the independent variable is zero.
Deming.
Supplier - input - process - output - customer.

48. What is Little's Law?
Initiated before or at design concept finalization
The number of standard deviations some value is from the mean.
Inventory = throughput x flow time.
Lower skill requirements - faster - less chance for error.

49. What is Jidoka?
Lower control limit.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Controlling quality at the source.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

50. What is the role of a green belt?
Different types of defects are listed (used for Pareto chart)
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Linearity - normality - homoscedasticity - independence.
To be a member of a Six Sigma project team.

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