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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. Failure Mode
Deming.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Is the way in which the failure is manifested.
QFD

2. Define yield.
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.
They move closer to the center line.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

3. What is DPMO?
The gap between what customers expect and the service they receive.
Producer risk.
Defects Per Million Opportunities
68%

4. Disadvantages of DOE

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5. What is the 5S model?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
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).
Fewer good units to sell - increased variable cost/unit.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

6. Who developed the fishbone diagram?
Defects Per Million Opportunities
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:
Kaoru Ishikawa.
68%

7. Creating a Run Chart
A diagram that shows the relationships between activities in a project network.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

8. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Critical to quality.
The target number of standard deviations from the mean for specifications.
Mean time to replacement.
68%

9. List Garvin's eight dimensions of product quality.
Kaoru Ishikawa.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
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

10. FMEA
68%
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
Controlling quality at the source.
Scrap - rework - retest - downtime - yield losses - disposition costs.

11. List two appraisal costs.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The gap between what customers expect and the service they receive.
Controlling quality at the source.
Method developed by Ishikawa to graphically display the causes of any given problem

12. Defect location check sheets
No -- only if the process is also capable.
Actual drawings - layouts - maps - etc which show where a defect occurs
To be a member of a Six Sigma project team.
A diagram that shows the relationships between activities in a project network.

13. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Variable.
Mean time to failure.
= yij - y(bar)i --> value minus sum of that treatment (of row)
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

14. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Used to create frequency distribution tally sheets
Prevention and appraisal costs are balanced against internal and external failure.
No -- if it is not the same - it can only be worse!
Fractional factorial designs (orthogonal arrays)

15. What quality tool formally incorporates the voice of the customer?
Is what induces the failure
The ability of a process to consistently meet customer specifications.
QFD
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

16. Defect check sheets
Can't tell without a Range chart.
Different types of defects are listed (used for Pareto chart)
A tool that shows where there is waste in a process.
Variable.

17. What are the three main categories of assignable cause?
Financial - customer - internal process - innovation and learning.
Workers - machines - materials.
The gap between what management thinks customers want and what customers really want.
To do a capability study for a non-centered process.

18. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
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
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
Represents the behavior of a process

19. What is an affinity diagram?
Hold all input variables constant except one. Observe the response as you vary the single input.
Workers - machines - materials.
A scatterplot.
A brainstorming tool that shows the connections between ideas.

20. What is a Gantt chart?
Shows the temporal flow of activities in a project network.
Supplier - input - process - output - customer.
To do a capability study for a non-centered process.
Observed variation in response is caused by the input

21. In the Service Quality Gap Model - what is Gap 1?
Initiated before or at design concept finalization
0.9^3 or 72.9%
The gap between what management thinks customers want and what customers really want.
Not necessarily.

22. What does SIPOC stand for?
Supplier - input - process - output - customer.
Pleasing to the senses.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Mean time to replacement.

23. 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
5%
F_alpha - df(tr) - df (error)
Lower skill requirements - faster - less chance for error.

24. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
Inventory = throughput x flow time.
A random variable that summarizes the information from the sample(s).
A descending order-sorted bar chart with a cumulative percentage line.

25. What is muda
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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
Waste.
Workers - machines - materials.

26. What does a project prioritization matrix do?
A random variable that summarizes the information from the sample(s).
Assigns scores to weighted criteria for each project under consideration.
A tool that shows where there is waste in a process.
To be a member of a Six Sigma project team.

27. In the Service Quality Gap Model - what is Gap 2?
Lean (or JIT).
The gap between what management thinks customers want and the process specifications.
Fitness for use.
Critical to quality.

28. ANOVA

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29. The Test Statistic (TS)
A random variable that summarizes the information from the sample(s).
Organize ideas into meaningful categories by recognizing their underlying similarity
Speed - courtesy - competence - and ease of repair.
Rapid improvement process.

30. Define conformance quality.
The degree to which a product meets pre-established standards.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Someone who is consistently against virtually everything.
Concluding there has been an effect/change when there has not.

31. Residual(eij)
A scatterplot.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
p-bar - the long-run percent defective.

32. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
100%
10 for Hazardous without warning 1 for none
=sqrt((p*(1-p)/n)
Outside.

33. Manual Test for Nomality
Large enough to find two of the attribute - on average.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Taguchi
Scrap - rework - retest - downtime - yield losses - disposition costs.

34. How does Juran define quality?
Fitness for use.
Failure Modes and Effects Analysis
Walter A. Shewhart
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

35. What is a dashboard?
To monitor a process when measurement by variables is used.
Lean is waste reduction - Six Sigma is variation reduction.
A tool that shows performance along key dimensions all at once.
10 if Almost impossible to detect

36. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
The primary operating characteristics of a product.
Look for the assignable cause of non-random variation.
Outside.

37. Complete this quality phrase: 'Fix the process - not the _____.'
Blame.
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
10 if Almost impossible to detect
Fractional factorial designs (orthogonal arrays)

38. What type of risk is associated with Type 1 Error?
A random variable that summarizes the information from the sample(s).
The ability of a process to consistently meet customer specifications.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Producer risk.

39. Affinity Diagrams
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
X-bar-bar
Critical to quality.
Producer risk.

40. Define takt time.
To obtain a certain desirable outcome from the process
If the Response vs. Levels graph if the response lines are not parallel (crossing)
100%
The cycle time required to meet demand.

41. What are the four perspectives of the Balanced Scorecard?
Financial - customer - internal process - innovation and learning.
95%
Sampling for SPC is done real time.
F_alpha - df(tr) - df (error)

42. What is the formula for standard deviation?
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:
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
A diagram that shows the relationships between activities in a project network.
=sqrt(Σ(x-x-bar)^2)/(n-1))

43. Your production process meets customer specifications. Is your process in control?
Not necessarily.
Method developed by Ishikawa to graphically display the causes of any given problem
Variable.
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

44. Define features.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The Japanese national quality award.
The secondary characteristics of a product; "bells and whistles."
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).

45. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
99.73%
Look for the assignable cause of non-random variation.
50%
Consumer risk.

46. Detection Criteria Ranking
Initiated before or at design concept finalization
Brand image.
10 if Almost impossible to detect
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).

47. Statistical Hypothesis
Conformance to specifications.
99.73%
An assertion or conjecture concerning one or more populations
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

48. If a Cp shows that a process is not capable - should you calculate Cpk?
No -- if it is not the same - it can only be worse!
Controlling quality at the source.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

49. Residual
A diagram that shows the relationships between activities in a project network.
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
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
10 for Hazardous without warning 1 for none

50. Failure effect
Lower skill requirements - faster - less chance for error.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Is the consequence of the failure.

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