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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 is muda
Linearity - normality - homoscedasticity - independence.
Actual drawings - layouts - maps - etc which show where a defect occurs
Waste.
The gap between what customers expect and the service they receive.

2. What is a network diagram?
Fewer good units to sell - increased variable cost/unit.
A diagram that shows the relationships between activities in a project network.
Not necessarily.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

3. Daniel Test
=sqrt((p*(1-p)/n)
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
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:
Fitness for use.

4. Residual(eij)
To monitor a process when measurement by variables is used.
= 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.
A descending order-sorted bar chart with a cumulative percentage line.

5. What is the role of a green belt?
Fitness for use.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Different types of defects are listed (used for Pareto chart)
To be a member of a Six Sigma project team.

6. What is Type II Error?
Concluding there has not been an effect/change when there has.
Method developed by Ishikawa to graphically display the causes of any given problem
Through producer/consumer negotiation.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

7. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
Kaoru Ishikawa.
Mean time to replacement.
Not necessarily.

8. 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.
5%
X-bar-bar
Deming.

9. Detection Criteria Ranking
10 if Almost impossible to detect
A tool that shows where there is waste in a process.
Is the way in which the failure is manifested.
95%

10. In the Service Quality Gap Model - what is Gap 2?
Speed - courtesy - competence - and ease of repair.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
A time series plot.
The gap between what management thinks customers want and the process specifications.

11. What is a histogram?
A tool that shows the physical flows through a space.
Actual drawings - layouts - maps - etc which show where a defect occurs
Hold all input variables constant except one. Observe the response as you vary the single input.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

12. TWO-DIMENTIONAL SCATTER PLOT
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Shifts - Trends - Repeating patterns - Correlation with known events
Look for the assignable cause of non-random variation.
0.9^3 or 72.9%

13. List two components of prevention cost.
Actual drawings - layouts - maps - etc which show where a defect occurs
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
The US national quality award.
A random variable that summarizes the information from the sample(s).

14. What is Jidoka?
Linearity - normality - homoscedasticity - independence.
Controlling quality at the source.
Consumer risk.
Lean (or JIT).

15. What is DPMO?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Workers - machines - materials.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Defects Per Million Opportunities

16. What quality tool formally incorporates the voice of the customer?
Workers - machines - materials.
A brainstorming tool that shows the connections between ideas.
Sampling for SPC is done real time.
QFD

17. Histogram by Hand
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
100%
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

18. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Outside.
No -- the variation also has to be random and "expected."
Kaoru Ishikawa.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

19. Who first studied randomness in industrial processes
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
Walter A. Shewhart
Fishbone - cause-and-effect diagram.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

20. What does SIPOC stand for?
Assigns scores to weighted criteria for each project under consideration.
Supplier - input - process - output - customer.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Mistake-proofing.

21. What is the 5S model?
100%
95%
Through producer/consumer negotiation.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

22. To what does the Six in Six Sigma relate?
Controlling quality at the source.
The target number of standard deviations from the mean for specifications.
Observed variation in response is caused by the input
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

23. Design of Experiments (DOE) approach
The target number of standard deviations from the mean for specifications.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Because the mean and standard deviation are independent of each other.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

24. List two appraisal costs.
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
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
The secondary characteristics of a product; "bells and whistles."

25. Define durability.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Mean time to replacement.
To be a member of a Six Sigma project team.
Fitness for use.

26. What is the center line of an X-bar chart?
A descending order-sorted bar chart with a cumulative percentage line.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
X-bar-bar
Consumer risk.

27. Define product reliability.
Waste.
To mentor/coach (and sometimes train) black belts.
The ratio of outputs to inputs; 1-scrap.
Mean time to failure.

28. Residual
0.9^3 or 72.9%
5%
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
100%

29. If you have calculated a Cpk - should you also calculate a Cp?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Stratify a particular defect type according to logical criteria
A random variable that summarizes the information from the sample(s).
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

30. Explain the difference between technical and functional service quality.
Method developed by Ishikawa to graphically display the causes of any given problem
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Technical quality is the "what" of the service; functional quality is the "how."
Is what induces the failure

31. What percentage of a normal distribution lies above the mean?
Kaoru Ishikawa.
10 for Hazardous without warning 1 for none
50%
Waste.

32. In a regression - what does the coefficient of the intercept tell you
The degree to which a product meets pre-established standards.
A time series plot.
Workers - machines - materials.
What the value of the dependent variable is when the independent variable is zero.

33. Regression
Causes that lead to a particular effect.
A tool that shows performance along key dimensions all at once.
Represents the behavior of a process
Used to create frequency distribution tally sheets

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

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35. Why do you need two control charts for variables SPC?
To manage the Six Sigma project.
= 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
Because the mean and standard deviation are independent of each other.
The House of Quality.

36. What happens to control limits on an SPC chart when sample size is increased?
=sqrt(Σ(x-x-bar)^2)/(n-1))
Financial - customer - internal process - innovation and learning.
Concluding there has been an effect/change when there has not.
They move closer to the center line.

37. When yields decrease - what are the two effects on contribution?
Fewer good units to sell - increased variable cost/unit.
95%
QFD
p-bar - the long-run percent defective.

38. Affinity Diagrams
The US national quality award.
Variable.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Attribute.

39. What is Little's Law?
Because the mean and standard deviation are independent of each other.
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
Inventory = throughput x flow time.
No -- only if the process is also capable.

40. Definition of Interaction
Lower skill requirements - faster - less chance for error.
Central Limit Theorem
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Scrap - rework - retest - downtime - yield losses - disposition costs.

41. What is DMADV?
Define - measure - analyze - design - verify.
Mistake-proofing.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Shifts - Trends - Repeating patterns - Correlation with known events

42. List two components of internal failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
5%
Through producer/consumer negotiation.

43. What is the center line of a p-chart?
p-bar - the long-run percent defective.
F_alpha - df(tr) - df (error)
Organize ideas into meaningful categories by recognizing their underlying similarity
5%

44. What size should samples be for attribute SPC?
Studying firms with the best performance in a particular area.
95%
Large enough to find two of the attribute - on average.
3.4 (assuming 1.5 sigma shift in the mean)

45. Stratified defect check sheets
Attribute
Initiated before or at design concept finalization
To monitor a process when measurement by attribute is used.
Stratify a particular defect type according to logical criteria

46. Define takt time.
The cycle time required to meet demand.
False - because each machine will have different natural tolerances.
Brand image.
A time series plot.

47. What is the Baldrige Award?
10 for Hazardous without warning 1 for none
The US national quality award.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Outside.

48. Define aesthetic quality.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Pleasing to the senses.
Organize ideas into meaningful categories by recognizing their underlying similarity
Assigns scores to weighted criteria for each project under consideration.

49. Defect location check sheets
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.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Large enough to find two of the attribute - on average.
Actual drawings - layouts - maps - etc which show where a defect occurs

50. FMEA
Fitness for use.
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
The gap between specifications and how service is performed.
Deming.

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Six Sigma

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