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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 type of risk is associated with Type II Error?
Consumer risk.
68%
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Taguchi

2. DOE
Initiated before or at design concept finalization
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
To do a capability study for a non-centered process.
10 if Almost impossible to detect

3. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
A tool that shows performance along key dimensions all at once.
Technical quality is the "what" of the service; functional quality is the "how."
Conformance to specifications.
Concluding there has been an effect/change when there has not.

4. What are two other names for an Ishikawa diagram?
Not necessarily.
Prevention - appraisal - internal failure - external failure.
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:
Fishbone - cause-and-effect diagram.

5. To what does the Six in Six Sigma relate?
The target number of standard deviations from the mean for specifications.
= 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
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
QFD

6. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
An assertion or conjecture concerning one or more populations
10 if Almost impossible to detect
The gap between what management thinks customers want and the process specifications.
95%

7. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Sampling for SPC is done real time.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Fitness for use.
X-bar-bar

8. What is a network diagram?
Deming.
A diagram that shows the relationships between activities in a project network.
To monitor a process when measurement by variables is used.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

9. FMEA
Technical quality is the "what" of the service; functional quality is the "how."
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
F_alpha - df(tr) - df (error)
Used to create frequency distribution tally sheets

10. What are the 5 Ss?
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
Method developed by Ishikawa to graphically display the causes of any given problem
Sort - Set in Order - Shine - Standardize - Sustain
The primary operating characteristics of a product.

11. Failure Mode
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Mean time to failure.
Kaoru Ishikawa.
Is the way in which the failure is manifested.

12. What is Kaizen?
Rapid improvement process.
Sampling for SPC is done real time.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

13. In the Service Quality Gap Model - what is Gap 5?
The gap between what customers expect and the service they receive.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Defects Per Million Opportunities
Used to create frequency distribution tally sheets

14. Test for constant variance
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
The gap between what is promised and what is delivered.
Initiated before or at design concept finalization
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.

15. What is a run chart?
A time series plot.
Sampling for SPC is done real time.
Stratify a particular defect type according to logical criteria
100%

16. Histogram by Hand
Inventory = throughput x flow time.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
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) 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

17. Which quality guru developed the concept of loss to society?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Initiated before or at design concept finalization
No -- the variation also has to be random and "expected."
Taguchi

18. Failure cause
What the value of the dependent variable is when the independent variable is zero.
10 if Almost impossible to detect
Is what induces the failure
Mean time to failure.

19. Explain the difference between technical and functional service quality.
Technical quality is the "what" of the service; functional quality is the "how."
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
No -- the variation also has to be random and "expected."
Inventory = throughput x flow time.

20. Residual
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Lower skill requirements - faster - less chance for error.
To obtain a certain desirable outcome from the process
Outside.

21. What is DPMO?
The target number of standard deviations from the mean for specifications.
Defects Per Million Opportunities
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.
10 for Hazardous without warning 1 for none

22. Define takt time.
The cycle time required to meet demand.
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
A descending order-sorted bar chart with a cumulative percentage line.
Method developed by Ishikawa to graphically display the causes of any given problem

23. With Six Sigma capability - how many defects per million opportunities would you see?
Kaoru Ishikawa.
3.4 (assuming 1.5 sigma shift in the mean)
The gap between what is promised and what is delivered.
Define - measure - analyze - improve - control.

24. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Stratify a particular defect type according to logical criteria
The gap between what is promised and what is delivered.
Can't tell without a Range chart.
99.73%

25. Define benchmarking.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Brand image.
Studying firms with the best performance in a particular area.
Defects Per Million Opportunities

26. Define product reliability.
95%
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
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Mean time to failure.

27. What is DMADV?
The House of Quality.
Define - measure - analyze - design - verify.
0.9^3 or 72.9%
The ratio of outputs to inputs; 1-scrap.

28. What is process capability?
Lower skill requirements - faster - less chance for error.
A brainstorming tool that shows the connections between ideas.
A descending order-sorted bar chart with a cumulative percentage line.
The ability of a process to consistently meet customer specifications.

29. FMEA
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
Linearity - normality - homoscedasticity - independence.
It looks to minimize the probability of a failure - or to minimize its effects
0.9^3 or 72.9%

30. Define durability.
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.
Conformance to specifications.
3.4 (assuming 1.5 sigma shift in the mean)
Mean time to replacement.

31. What does SIPOC stand for?
Supplier - input - process - output - customer.
Waste.
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.
The gap between specifications and how service is performed.

32. In a regression - what does the p value of F tell you?
Assigns scores to weighted criteria for each project under consideration.
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).
Attribute
QFD

33. If you have calculated a Cpk - should you also calculate a Cp?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
To do a capability study for a non-centered process.
Initiated before or at design concept finalization
Sampling for SPC is done real time.

34. Regression Analysis
A tool that shows performance along key dimensions all at once.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
An assertion or conjecture concerning one or more populations
To do a capability study for a non-centered process.

35. When is Cpk used?
It looks to minimize the probability of a failure - or to minimize its effects
Can't tell without a Range chart.
=sqrt((p*(1-p)/n)
To do a capability study for a non-centered process.

36. What is poka yoke?
Mistake-proofing.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
No -- the variation also has to be random and "expected."

37. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
F_alpha - df(tr) - df (error)
= yij - y(bar)i --> value minus sum of that treatment (of row)
100%
The gap between what management thinks customers want and the process specifications.

38. Process occurance ranking
Variable.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Critical to quality.
10 for Hazardous without warning 1 for none

39. What is the role of a black belt?
Is the way in which the failure is manifested.
To manage the Six Sigma project.
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:
Lean is waste reduction - Six Sigma is variation reduction.

40. Does it ever make sense to accept a job when a process is incapable?
The gap between what management thinks customers want and what customers really want.
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
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Fitness for use.

41. How are LQL and AQL determined in an acceptance sampling plan?
Through producer/consumer negotiation.
Technical quality is the "what" of the service; functional quality is the "how."
Look for the assignable cause of non-random variation.
Taguchi

42. Uses of regression - Control
Supplier - input - process - output - customer.
To obtain a certain desirable outcome from the process
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Sampling for SPC is done real time.

43. What is the difference between Lean and Six Sigma?
The gap between what management thinks customers want and the process specifications.
10 if Almost impossible to detect
Inventory = throughput x flow time.
Lean is waste reduction - Six Sigma is variation reduction.

44. List Garvin's eight dimensions of product quality.
Shows the temporal flow of activities in a project network.
The Japanese national quality award.
A random variable that summarizes the information from the sample(s).
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

45. ANOVA

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46. Regression
Attribute.
Supplier - input - process - output - customer.
A random variable that summarizes the information from the sample(s).
Represents the behavior of a process

47. Define yield.
The degree to which a product meets pre-established standards.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Actual drawings - layouts - maps - etc which show where a defect occurs
The ratio of outputs to inputs; 1-scrap.

48. Daniel Test
The cycle time required to meet demand.
100%
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
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:

49. Detection Criteria Ranking
Is the consequence of the failure.
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
10 if Almost impossible to detect
Mean time to replacement.

50. Residual(eij)
Conformance to specifications.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Large enough to find two of the attribute - on average.
Represents the behavior of a process

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