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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.
Don't refresh. All questions and answers are randomly picked and ordered every time you load a test.

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. If you have calculated a Cpk - should you also calculate a Cp?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
The gap between what is promised and what is delivered.
Through producer/consumer negotiation.

2. Defect check sheets
A tool that shows the physical flows through a space.
Different types of defects are listed (used for Pareto chart)
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Represents the behavior of a process

3. What is the formula for the standard deviation of a proportion?
Through producer/consumer negotiation.
=sqrt((p*(1-p)/n)
A random variable that summarizes the information from the sample(s).
Reliability - Assurance - Responsiveness - Tangibles - Empathy

4. Residual(eij)
= yij - y(bar)i --> value minus sum of that treatment (of row)
p-bar - the long-run percent defective.
To manage the Six Sigma project.
Is the way in which the failure is manifested.

5. What is the center line of an X-bar chart?
Lean (or JIT).
To mentor/coach (and sometimes train) black belts.
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:
X-bar-bar

6. In a regression - what does the standard error of the estimate tell you?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Sort - Set in Order - Shine - Standardize - Sustain
The House of Quality.
The target number of standard deviations from the mean for specifications.

7. What is a run chart?
A time series plot.
Used to create frequency distribution tally sheets
To do a capability study for a non-centered process.
Studying firms with the best performance in a particular area.

8. Define product reliability.
Mean time to failure.
Pleasing to the senses.
Is the consequence of the failure.
Failure Modes and Effects Analysis

9. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Is what induces the failure
No -- the variation also has to be random and "expected."
A tool that shows performance along key dimensions all at once.

10. Define benchmarking.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
No -- if it is not the same - it can only be worse!
10 if Almost impossible to detect
Studying firms with the best performance in a particular area.

11. Failure cause
Failure Modes and Effects Analysis
Before production starts
Consumer risk.
Is what induces the failure

12. What do you do when a process is out of control?
Initiated before or at design concept finalization
Look for the assignable cause of non-random variation.
No -- the variation also has to be random and "expected."
Reliability - Assurance - Responsiveness - Tangibles - Empathy

13. What does SIPOC stand for?
A tool that shows performance along key dimensions all at once.
Blame.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Supplier - input - process - output - customer.

14. What is a CAVE man?
The House of Quality.
Someone who is consistently against virtually everything.
Used to create frequency distribution tally sheets
To monitor a process when measurement by variables is used.

15. What are the three main categories of assignable cause?
Workers - machines - materials.
p-bar - the long-run percent defective.
The House of Quality.
An assertion or conjecture concerning one or more populations

16. Regression
No -- the variation also has to be random and "expected."
Lower control limit.
Brand image.
Represents the behavior of a process

17. What is Jidoka?
Walter A. Shewhart
A scatterplot.
To be a member of a Six Sigma project team.
Controlling quality at the source.

18. Who first studied randomness in industrial processes
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Sampling for SPC is done real time.
Is what induces the failure
Walter A. Shewhart

19. Presence of interaction effect
No -- only if the process is also capable.
Shifts - Trends - Repeating patterns - Correlation with known events
If the Response vs. Levels graph if the response lines are not parallel (crossing)
To mentor/coach (and sometimes train) black belts.

20. Define performance quality.
The primary operating characteristics of a product.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Prevention - appraisal - internal failure - external failure.
The ratio of outputs to inputs; 1-scrap.

21. Detection Criteria Ranking
10 if Almost impossible to detect
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Pleasing to the senses.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

22. Which type of SPC measurement is more precise - variable or attribute?
Pleasing to the senses.
Variable.
Brand image.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

23. What are the 5 Ss?
Sort - Set in Order - Shine - Standardize - Sustain
Is the way in which the failure is manifested.
Look for the assignable cause of non-random variation.
A scatterplot.

24. Process check sheets
Used to create frequency distribution tally sheets
F_alpha - df(tr) - df (error)
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
=sqrt((p*(1-p)/n)

25. Define yield.
Mean time to failure.
A scatterplot.
The ratio of outputs to inputs; 1-scrap.
It looks to minimize the probability of a failure - or to minimize its effects

26. Design of Experiments (DOE) approach
10 if Almost impossible to detect
Technical quality is the "what" of the service; functional quality is the "how."
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Controlling quality at the source.

27. Test for Independence
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
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.
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
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

28. What are the Five Dimensions of Service Quality?
What the value of the dependent variable is when the independent variable is zero.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
A brainstorming tool that shows the connections between ideas.
Conformance to specifications.

29. What is the difference between Lean and Six Sigma?
To manage the Six Sigma project.
Hold all input variables constant except one. Observe the response as you vary the single input.
Lean is waste reduction - Six Sigma is variation reduction.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

30. Uses of regression
Speed - courtesy - competence - and ease of repair.
Sampling for SPC is done real time.
The number of standard deviations some value is from the mean.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

31. What is FMEA?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The target number of standard deviations from the mean for specifications.
Failure Modes and Effects Analysis
The US national quality award.

32. Failure Mode
Lower skill requirements - faster - less chance for error.
A brainstorming tool that shows the connections between ideas.
Is the way in which the failure is manifested.
Method developed by Ishikawa to graphically display the causes of any given problem

33. In a regression - what does the coefficient of the intercept tell you
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).
Lean is waste reduction - Six Sigma is variation reduction.
What the value of the dependent variable is when the independent variable is zero.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

34. Define perceived quality (Garvin's framework).
Scrap - rework - retest - downtime - yield losses - disposition costs.
Controlling quality at the source.
Conformance to specifications.
Brand image.

35. Risk Priority Number RPN
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Speed - courtesy - competence - and ease of repair.

36. One factor at a time (OFAT)
Different types of defects are listed (used for Pareto chart)
A random variable that summarizes the information from the sample(s).
No -- if it is not the same - it can only be worse!
Hold all input variables constant except one. Observe the response as you vary the single input.

37. Define conformance quality.
Waste.
The degree to which a product meets pre-established standards.
Producer risk.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

38. F value
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
F_alpha - df(tr) - df (error)
Scrap - rework - retest - downtime - yield losses - disposition costs.
The Japanese national quality award.

39. What is the center line of a p-chart?
p-bar - the long-run percent defective.
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
Someone who is consistently against virtually everything.
Attribute.

40. If a Cp shows that a process is not capable - should you calculate Cpk?
Consumer risk.
No -- the variation also has to be random and "expected."
No -- if it is not the same - it can only be worse!
Blame.

41. In the Service Quality Gap Model - what is Gap 5?
Someone who is consistently against virtually everything.
The gap between what customers expect and the service they receive.
The ratio of outputs to inputs; 1-scrap.
Producer risk.

42. Based on what principal can we use the normal distribution assumptions for SPC?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Method developed by Ishikawa to graphically display the causes of any given problem
Central Limit Theorem
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

43. Which quality guru developed the concept of loss to society?
Because the mean and standard deviation are independent of each other.
Taguchi
It looks to minimize the probability of a failure - or to minimize its effects
To do a capability study for a non-centered process.

44. What is a dashboard?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
=sqrt(Σ(x-x-bar)^2)/(n-1))
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
A tool that shows performance along key dimensions all at once.

45. Affinity Diagrams
Is the way in which the failure is manifested.
A tool that shows the physical flows through a space.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

46. DOE
Stratify a particular defect type according to logical criteria
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Observed variation in response is caused by the input
Organize ideas into meaningful categories by recognizing their underlying similarity

47. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Used to create frequency distribution tally sheets
The gap between what management thinks customers want and the process specifications.
Sort - Set in Order - Shine - Standardize - Sustain
Outside.

48. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
99.73%
Variable.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

49. Effect ranking (Severity of the Defect)
Controlling quality at the source.
10 for Hazardous without warning 1 for none
F_alpha - df(tr) - df (error)
A brainstorming tool that shows the connections between ideas.

50. Failure effect
3.4 (assuming 1.5 sigma shift in the mean)
Attribute.
Concluding there has not been an effect/change when there has.
Is the consequence of the failure.

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Six Sigma

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