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Six Sigma

Subjects : certifications, six-sigma, business-skills

Instructions:

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 type of risk is associated with Type II Error?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Consumer risk.
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.
Central Limit Theorem

2. Cause and Effect Diagrams
A scatterplot.
Method developed by Ishikawa to graphically display the causes of any given problem
Is the way in which the failure is manifested.
Studying firms with the best performance in a particular area.

3. For what is an x-bar chart used?
Is what induces the failure
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
To be a member of a Six Sigma project team.
To monitor a process when measurement by variables is used.

4. What does SIPOC stand for?
No -- only if the process is also capable.
Supplier - input - process - output - customer.
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.

5. Defect location check sheets
99.73%
Deming.
The gap between specifications and how service is performed.
Actual drawings - layouts - maps - etc which show where a defect occurs

6. What is a CAVE man?
Inventory = throughput x flow time.
Is what induces the failure
Someone who is consistently against virtually everything.
Lean is waste reduction - Six Sigma is variation reduction.

7. DOE
The number of standard deviations some value is from the mean.
50%
Upper control limit.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

8. What does the abbreviation UCL stand for?
Can't tell without a Range chart.
Upper control limit.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
A scatterplot.

9. A process is operating "in control." Does this mean the customer's requirements are met?
No -- only if the process is also capable.
The House of Quality.
Speed - courtesy - competence - and ease of repair.
Blame.

10. What is the formula for standard deviation?
Taguchi
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Lower skill requirements - faster - less chance for error.
=sqrt(Σ(x-x-bar)^2)/(n-1))

11. One factor at a time (OFAT)
Observed variation in response is caused by the input
Studying firms with the best performance in a particular area.
Look for the assignable cause of non-random variation.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

12. What percentage of a normal distribution lies above the mean?
A tool that shows where there is waste in a process.
Large enough to find two of the attribute - on average.
The gap between what management thinks customers want and the process specifications.
50%

13. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
A time series plot.
Failure Modes and Effects Analysis
A tool that shows performance along key dimensions all at once.
Lower skill requirements - faster - less chance for error.

14. What is the center line of a p-chart?
Mistake-proofing.
Technical quality is the "what" of the service; functional quality is the "how."
p-bar - the long-run percent defective.
Deming.

15. Definition of Interaction
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
95%
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
To obtain a certain desirable outcome from the process

16. What is the 5S model?
Variable.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
What the value of the dependent variable is when the independent variable is zero.
The House of Quality.

17. Effect ranking (Severity of the Defect)
Financial - customer - internal process - innovation and learning.
10 for Hazardous without warning 1 for none
Can't tell without a Range chart.
Define - measure - analyze - design - verify.

18. In a regression - what does the standard error of the estimate tell you?
Critical to quality.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Brand image.
Mean time to failure.

19. Regression
The gap between specifications and how service is performed.
Represents the behavior of a process
Waste.
Fishbone - cause-and-effect diagram.

20. Who first studied randomness in industrial processes
Sampling for SPC is done real time.
Supplier - input - process - output - customer.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Walter A. Shewhart

21. One factor at a time (OFAT)
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Define - measure - analyze - improve - control.
Hold all input variables constant except one. Observe the response as you vary the single input.

22. What is poka yoke?
To manage the Six Sigma project.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Stratify a particular defect type according to logical criteria
Mistake-proofing.

23. What is a Gantt chart?
Shows the temporal flow of activities in a project network.
They move closer to the center line.
Through producer/consumer negotiation.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

24. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
They move closer to the center line.
X-bar-bar
5%
The US national quality award.

25. What is written on the "spines" of a fishbone diagram?
Causes that lead to a particular effect.
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
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Represents the behavior of a process

26. PFMEA
Mean time to failure.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Before production starts
QFD

27. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
99.73%
Waste.
0.9^3 or 72.9%
Prevention and appraisal costs are balanced against internal and external failure.

28. Affinity Diagrams
The ability of a process to consistently meet customer specifications.
To mentor/coach (and sometimes train) black belts.
Organize ideas into meaningful categories by recognizing their underlying similarity
To do a capability study for a non-centered process.

29. What does a project prioritization matrix do?
Assigns scores to weighted criteria for each project under consideration.
Actual drawings - layouts - maps - etc which show where a defect occurs
Speed - courtesy - competence - and ease of repair.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

30. Define durability.
Used to create frequency distribution tally sheets
Prevention - appraisal - internal failure - external failure.
Mean time to replacement.
To be a member of a Six Sigma project team.

31. What does DMAIC stand for?
The Japanese national quality award.
Define - measure - analyze - improve - control.
The US national quality award.
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.

32. DFMEA
Define - measure - analyze - improve - control.
Initiated before or at design concept finalization
Upper control limit.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

33. Who is a process owner?
Financial - customer - internal process - innovation and learning.
Pleasing to the senses.
Fewer good units to sell - increased variable cost/unit.
The manager in charge of a process being improved in a Six Sigma project.

34. What is an affinity diagram?
Concluding there has not been an effect/change when there has.
Used to create frequency distribution tally sheets
Not necessarily.
A brainstorming tool that shows the connections between ideas.

35. For what is a p-chart used?
Deming.
To monitor a process when measurement by attribute is used.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
To do a capability study for a non-centered process.

36. What is the difference between Lean and Six Sigma?
Lean is waste reduction - Six Sigma is variation reduction.
Observed variation in response is caused by the input
Defects Per Million Opportunities
Lower control limit.

37. List Garvin's eight dimensions of product quality.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
The ability of a process to consistently meet customer specifications.
Brand image.
Technical quality is the "what" of the service; functional quality is the "how."

38. What is a network diagram?
A diagram that shows the relationships between activities in a project network.
A descending order-sorted bar chart with a cumulative percentage line.
Mean time to replacement.
The gap between specifications and how service is performed.

39. What size should samples be for attribute SPC?
Large enough to find two of the attribute - on average.
Fishbone - cause-and-effect diagram.
Failure Modes and Effects Analysis
Controlling quality at the source.

40. Test for constant variance
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
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.
Shifts - Trends - Repeating patterns - Correlation with known events
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

41. Failure Mode
Consumer risk.
Lean (or JIT).
Is the way in which the failure is manifested.
X-bar-bar

42. Based on what principal can we use the normal distribution assumptions for SPC?
99.73%
Someone who is consistently against virtually everything.
Through producer/consumer negotiation.
Central Limit Theorem

43. If you can only collect categorical data - what type of SPC charting can you do?
100%
Attribute.
Can't tell without a Range chart.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

44. 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.
Technical quality is the "what" of the service; functional quality is the "how."
To mentor/coach (and sometimes train) black belts.
Mistake-proofing.

45. What is the center line of an X-bar chart?
Failure Modes and Effects Analysis
Represents the behavior of a process
X-bar-bar
To manage the Six Sigma project.

46. Residual(eij)
A descending order-sorted bar chart with a cumulative percentage line.
Waste.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Lean (or JIT).

47. The Test Statistic (TS)
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Linearity - normality - homoscedasticity - independence.
A random variable that summarizes the information from the sample(s).
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

48. Complete this quality phrase: 'Fix the process - not the _____.'
An assertion or conjecture concerning one or more populations
Blame.
The gap between what customers expect and the service they receive.
The gap between what management thinks customers want and the process specifications.

49. Define takt time.
The cycle time required to meet demand.
The gap between what customers expect and the service they receive.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

50. Advantages of DOE
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
Prevention - appraisal - internal failure - external failure.
Blame.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

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