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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. If a Cp shows that a process is not capable - should you calculate Cpk?
0.9^3 or 72.9%
No -- if it is not the same - it can only be worse!
An assertion or conjecture concerning one or more populations
Supplier - input - process - output - customer.

2. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
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
Variable.
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

3. Manual Test for Nomality
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
No -- only if the process is also capable.
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.
A scatterplot.

4. Risk Priority Number RPN
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
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
Fewer good units to sell - increased variable cost/unit.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

5. The data points on an SPC p-chart of defective percent plot below the mean. Is this good or bad?

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6. With Six Sigma capability - how many defects per million opportunities would you see?
3.4 (assuming 1.5 sigma shift in the mean)
Lean (or JIT).
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
A descending order-sorted bar chart with a cumulative percentage line.

7. What is DPMO?
Prevention - appraisal - internal failure - external failure.
No -- the variation also has to be random and "expected."
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Defects Per Million Opportunities

8. PFMEA
Can't tell without a Range chart.
Before production starts
Workers - machines - materials.
5%

9. What are the four categories of costs in Juran's framework?
Inventory = throughput x flow time.
Prevention - appraisal - internal failure - external failure.
Mean time to replacement.
Fishbone - cause-and-effect diagram.

10. Define benchmarking.
To manage the Six Sigma project.
Studying firms with the best performance in a particular area.
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
The ratio of outputs to inputs; 1-scrap.

11. Residual
The cycle time required to meet demand.
Observed variation in response is caused by the input
Is what induces the failure
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

12. If you have calculated a Cpk - should you also calculate a Cp?
A tool that shows performance along key dimensions all at once.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
A time series plot.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

13. Design of Experiments (DOE) approach
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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
The gap between what customers expect and the service they receive.
Someone who is consistently against virtually everything.

14. What is poka yoke?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Mistake-proofing.
Taguchi
Is the consequence of the failure.

15. What is an affinity diagram?
A time series plot.
A brainstorming tool that shows the connections between ideas.
Fitness for use.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

16. What is DMADV?
Consumer risk.
Lower skill requirements - faster - less chance for error.
Define - measure - analyze - design - verify.
Fitness for use.

17. Test for constant variance
50%
= 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
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.
Can't tell without a Range chart.

18. FMEA
To monitor a process when measurement by variables is used.
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
A scatterplot.
Fitness for use.

19. In the Service Quality Gap Model - what is Gap 2?
Lower control limit.
The gap between what management thinks customers want and the process specifications.
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
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

20. What quality guru emphasizes management as a system?
To mentor/coach (and sometimes train) black belts.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Deming.
Outside.

21. What is Type II Error?
Failure Modes and Effects Analysis
Inventory = throughput x flow time.
Concluding there has not been an effect/change when there has.
The gap between what management thinks customers want and what customers really want.

22. Detection Criteria Ranking
Concluding there has been an effect/change when there has not.
10 if Almost impossible to detect
Is the way in which the failure is manifested.
Kaoru Ishikawa.

23. One factor at a time (OFAT)
Observed variation in response is caused by the input
100%
10 for Hazardous without warning 1 for none
Can't tell without a Range chart.

24. What is the role of a black belt?
To manage the Six Sigma project.
Lower control limit.
Inventory = throughput x flow time.
Is the way in which the failure is manifested.

25. If a three-stage process has 90% yields at each stage - what is the overall yield?
To do a capability study for a non-centered process.
Concluding there has not been an effect/change when there has.
Sort - Set in Order - Shine - Standardize - Sustain
0.9^3 or 72.9%

26. The Test Statistic (TS)
Sort - Set in Order - Shine - Standardize - Sustain
A random variable that summarizes the information from the sample(s).
0.9^3 or 72.9%
A descending order-sorted bar chart with a cumulative percentage line.

27. What is the 5S model?
Taguchi
Mean time to failure.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Variable.

28. What is a CAVE man?
Shifts - Trends - Repeating patterns - Correlation with known events
The secondary characteristics of a product; "bells and whistles."
10 if Almost impossible to detect
Someone who is consistently against virtually everything.

29. F value
F_alpha - df(tr) - df (error)
Define - measure - analyze - design - verify.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Someone who is consistently against virtually everything.

30. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Is what induces the failure
Variable.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Fishbone - cause-and-effect diagram.

31. Defect location check sheets
Used to create frequency distribution tally sheets
A scatterplot.
Represents the behavior of a process
Actual drawings - layouts - maps - etc which show where a defect occurs

32. Disadvantages of DOE

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33. What are the Five Dimensions of Service Quality?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Technical quality is the "what" of the service; functional quality is the "how."
Defects Per Million Opportunities
A diagram that shows the relationships between activities in a project network.

34. Non-random patterns (Run Charts)
Shifts - Trends - Repeating patterns - Correlation with known events
Is what induces the failure
The secondary characteristics of a product; "bells and whistles."
Producer risk.

35. How does Juran define quality?
QFD
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Fitness for use.
Organize ideas into meaningful categories by recognizing their underlying similarity

36. Process occurance ranking
A diagram that shows the relationships between activities in a project network.
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
95%

37. Your production process meets customer specifications. Is your process in control?
Lean is waste reduction - Six Sigma is variation reduction.
Not necessarily.
5%
Fitness for use.

38. Process check sheets
Conformance to specifications.
10 for Hazardous without warning 1 for none
Waste.
Used to create frequency distribution tally sheets

39. What type of risk is associated with Type II Error?
Financial - customer - internal process - innovation and learning.
Consumer risk.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

40. Does it ever make sense to accept a job when a process is incapable?
= 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
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Fishbone - cause-and-effect diagram.
Because the mean and standard deviation are independent of each other.

41. List Garvin's eight dimensions of product quality.
No -- the variation also has to be random and "expected."
Financial - customer - internal process - innovation and learning.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Define - measure - analyze - design - verify.

42. 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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43. What is Jidoka?
Controlling quality at the source.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
No -- only if the process is also capable.
Linearity - normality - homoscedasticity - independence.

44. What is Value Stream Mapping?
=sqrt((p*(1-p)/n)
A tool that shows where there is waste in a process.
A time series plot.
Prevention and appraisal costs are balanced against internal and external failure.

45. ANOVA

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46. FMEA
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
It looks to minimize the probability of a failure - or to minimize its effects
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
Fractional factorial designs (orthogonal arrays)

47. What does a project prioritization matrix do?
Assigns scores to weighted criteria for each project under consideration.
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
Fitness for use.
Different types of defects are listed (used for Pareto chart)

48. In a regression - what does the standard error of the estimate tell you?
Taguchi
Is the consequence of the failure.
The manager in charge of a process being improved in a Six Sigma project.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

49. What does the abbreviation UCL stand for?
Upper control limit.
The ratio of outputs to inputs; 1-scrap.
A tool that shows where there is waste in a process.
Through producer/consumer negotiation.

50. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Lower control limit.
QFD
Prevention - appraisal - internal failure - external failure.
5%

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