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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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1. What is the Baldrige Award?
5%
Define - measure - analyze - design - verify.
Prevention and appraisal costs are balanced against internal and external failure.
The US national quality award.

2. Defect location check sheets
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
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).
To be a member of a Six Sigma project team.
Actual drawings - layouts - maps - etc which show where a defect occurs

3. In the Service Quality Gap Model - what is Gap 4?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
The gap between what is promised and what is delivered.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
To manage the Six Sigma project.

4. What are the Five Dimensions of Service Quality?
Kaoru Ishikawa.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Producer risk.
Technical quality is the "what" of the service; functional quality is the "how."

5. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
To be a member of a Six Sigma project team.
Producer risk.
No -- the variation also has to be random and "expected."
5%

6. Which quality guru developed the concept of loss to society?
Taguchi
The ability of a process to consistently meet customer specifications.
Causes that lead to a particular effect.
A scatterplot.

7. Non-random patterns (Run Charts)
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Used to create frequency distribution tally sheets
Shifts - Trends - Repeating patterns - Correlation with known events
Mean time to replacement.

8. What is the role of a master black belt?
To mentor/coach (and sometimes train) black belts.
Can't tell without a Range chart.
Mistake-proofing.
Conformance to specifications.

9. What is Jidoka?
10 for Hazardous without warning 1 for none
5%
The secondary characteristics of a product; "bells and whistles."
Controlling quality at the source.

10. For what is a p-chart used?
A time series plot.
To monitor a process when measurement by attribute is used.
It's good -- but it's still out of control!
Blame.

11. What does the abbreviation LCL stand for?
Lower control limit.
Mean time to failure.
Lean (or JIT).
Is what induces the failure

12. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Variable.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Can't tell without a Range chart.
Concluding there has been an effect/change when there has not.

13. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
F_alpha - df(tr) - df (error)
False - because each machine will have different natural tolerances.
Lower skill requirements - faster - less chance for error.
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

14. What do you do when a process is out of control?
The gap between specifications and how service is performed.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Look for the assignable cause of non-random variation.
Outside.

15. 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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16. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
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
Failure Modes and Effects Analysis
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:

17. Define product reliability.
Mean time to failure.
The Japanese national quality award.
Waste.
Supplier - input - process - output - customer.

18. What is poka yoke?
Initiated before or at design concept finalization
Mistake-proofing.
The Japanese national quality award.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

19. For what is an x-bar chart used?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Sampling for SPC is done real time.
The gap between specifications and how service is performed.
To monitor a process when measurement by variables is used.

20. What are the 5 Ss?
Pleasing to the senses.
Sort - Set in Order - Shine - Standardize - Sustain
10 if Almost impossible to detect
The gap between what management thinks customers want and what customers really want.

21. What is Type II Error?
Concluding there has not been an effect/change when there has.
Someone who is consistently against virtually everything.
Waste.
3.4 (assuming 1.5 sigma shift in the mean)

22. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Large enough to find two of the attribute - on average.
50%
Attribute
F_alpha - df(tr) - df (error)

23. Test for Independence
No -- the variation also has to be random and "expected."
Technical quality is the "what" of the service; functional quality is the "how."
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
Shows the temporal flow of activities in a project network.

24. Failure Mode
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Is the way in which the failure is manifested.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Assigns scores to weighted criteria for each project under consideration.

25. What is the center line of an X-bar chart?
68%
What the value of the dependent variable is when the independent variable is zero.
Blame.
X-bar-bar

26. What is a network diagram?
The ratio of outputs to inputs; 1-scrap.
Shifts - Trends - Repeating patterns - Correlation with known events
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
A diagram that shows the relationships between activities in a project network.

27. Creating a Run Chart
3.4 (assuming 1.5 sigma shift in the mean)
Define - measure - analyze - design - verify.
Stratify a particular defect type according to logical criteria
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

28. In the Service Quality Gap Model - what is Gap 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:
Shows the temporal flow of activities in a project network.
Prevention and appraisal costs are balanced against internal and external failure.
The gap between what management thinks customers want and what customers really want.

29. In a regression - what does R-square tell you?
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.
Organize ideas into meaningful categories by recognizing their underlying similarity
= 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
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

30. Why do you need two control charts for variables SPC?
The Japanese national quality award.
Because the mean and standard deviation are independent of each other.
Lower skill requirements - faster - less chance for error.
Consumer risk.

31. Daniel Test
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:
Rapid improvement process.
To obtain a certain desirable outcome from the process
If the Response vs. Levels graph if the response lines are not parallel (crossing)

32. Who first studied randomness in industrial processes
A tool that shows performance along key dimensions all at once.
Concluding there has not been an effect/change when there has.
Walter A. Shewhart
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

33. F value
Is the consequence of the failure.
Concluding there has not been an effect/change when there has.
Rapid improvement process.
F_alpha - df(tr) - df (error)

34. Design of Experiments (DOE) approach
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
99.73%
Walter A. Shewhart
Is the way in which the failure is manifested.

35. How are LQL and AQL determined in an acceptance sampling plan?
Organize ideas into meaningful categories by recognizing their underlying similarity
Through producer/consumer negotiation.
It looks to minimize the probability of a failure - or to minimize its effects
Fitness for use.

36. In a regression - what does the p value of F tell you?
Different types of defects are listed (used for Pareto chart)
Causes that lead to a particular effect.
The secondary characteristics of a product; "bells and whistles."
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).

37. What is the 5S model?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Because the mean and standard deviation are independent of each other.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Fitness for use.

38. Does it ever make sense to accept a job when a process is incapable?
The ability of a process to consistently meet customer specifications.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

39. Name the structure associated with Quality Function Deployment.
Different types of defects are listed (used for Pareto chart)
No -- if it is not the same - it can only be worse!
The House of Quality.
Financial - customer - internal process - innovation and learning.

40. Define yield.
The ratio of outputs to inputs; 1-scrap.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Mistake-proofing.
Central Limit Theorem

41. DFMEA
Initiated before or at design concept finalization
Mean time to replacement.
The secondary characteristics of a product; "bells and whistles."
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

42. What is a Gage R&R?
No -- only if the process is also capable.
0.9^3 or 72.9%
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).
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

43. Cause and Effect Diagrams
=sqrt(Σ(x-x-bar)^2)/(n-1))
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Attribute
Method developed by Ishikawa to graphically display the causes of any given problem

44. What does DMAIC stand for?
Define - measure - analyze - design - verify.
To manage the Six Sigma project.
Define - measure - analyze - improve - control.
A scatterplot.

45. The Test Statistic (TS)
Hold all input variables constant except one. Observe the response as you vary the single input.
A random variable that summarizes the information from the sample(s).
Walter A. Shewhart
Observed variation in response is caused by the input

46. What is a run chart?
Observed variation in response is caused by the input
Is what induces the failure
Organize ideas into meaningful categories by recognizing their underlying similarity
A time series plot.

47. What does Crosby say about benchmarking?
5%
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
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
Concluding there has not been an effect/change when there has.

48. What is process capability?
Attribute.
Walter A. Shewhart
The ability of a process to consistently meet customer specifications.
The ratio of outputs to inputs; 1-scrap.

49. What is the role of a black belt?
To manage the Six Sigma project.
Different types of defects are listed (used for Pareto chart)
QFD
It looks to minimize the probability of a failure - or to minimize its effects

50. What is muda
Waste.
Fishbone - cause-and-effect diagram.
Financial - customer - internal process - innovation and learning.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

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