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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 are the four categories of costs in Juran's framework?
No -- the variation also has to be random and "expected."
Prevention - appraisal - internal failure - external failure.
Different types of defects are listed (used for Pareto chart)
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

2. Define performance quality.
Workers - machines - materials.
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 primary operating characteristics of a product.
Attribute.

3. Regression
Represents the behavior of a process
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
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.
Concluding there has not been an effect/change when there has.

4. Cause and Effect Diagrams
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
It looks to minimize the probability of a failure - or to minimize its effects
The gap between what management thinks customers want and what customers really want.
Method developed by Ishikawa to graphically display the causes of any given problem

5. Name the structure associated with Quality Function Deployment.
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.
No -- the variation also has to be random and "expected."
The House of Quality.
Conformance to specifications.

6. 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.
Pleasing to the senses.
Concluding there has not been an effect/change when there has.

7. Residual(eij)
Look for the assignable cause of non-random variation.
The House of Quality.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Fewer good units to sell - increased variable cost/unit.

8. What is DPMO?
Variable.
A time series plot.
Defects Per Million Opportunities
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

9. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
10 if Almost impossible to detect
Rapid improvement process.
=sqrt((p*(1-p)/n)
Variable.

10. What is a spaghetti diagram?
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
The Japanese national quality award.
Outside.
A tool that shows the physical flows through a space.

11. Define conformance quality.
Is what induces the failure
The degree to which a product meets pre-established standards.
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
Reliability - Assurance - Responsiveness - Tangibles - Empathy

12. What does a project prioritization matrix do?
Different types of defects are listed (used for Pareto chart)
Lower skill requirements - faster - less chance for error.
Assigns scores to weighted criteria for each project under consideration.
The House of Quality.

13. What is an affinity diagram?
A brainstorming tool that shows the connections between ideas.
Before production starts
The House of Quality.
Rapid improvement process.

14. Uses of regression - Control
Outside.
Failure Modes and Effects Analysis
Supplier - input - process - output - customer.
To obtain a certain desirable outcome from the process

15. Simple Regression Analysis (one factor regression model)
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Different types of defects are listed (used for Pareto chart)
= 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
Reliability - Assurance - Responsiveness - Tangibles - Empathy

16. What are the Five Dimensions of Service Quality?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Variable.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Controlling quality at the source.

17. Failure cause
Financial - customer - internal process - innovation and learning.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Is what induces the failure
Used to create frequency distribution tally sheets

18. What is a Pareto chart?
The gap between what customers expect and the service they receive.
=sqrt((p*(1-p)/n)
The cycle time required to meet demand.
A descending order-sorted bar chart with a cumulative percentage line.

19. What is Little's Law?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Inventory = throughput x flow time.
Workers - machines - materials.
To manage the Six Sigma project.

20. Statistical Hypothesis
Mistake-proofing.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
An assertion or conjecture concerning one or more populations
The target number of standard deviations from the mean for specifications.

21. What is the difference between Lean and Six Sigma?
The primary operating characteristics of a product.
Lean is waste reduction - Six Sigma is variation reduction.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
No -- if it is not the same - it can only be worse!

22. Explain the difference between technical and functional service quality.
The cycle time required to meet demand.
Assigns scores to weighted criteria for each project under consideration.
A time series plot.
Technical quality is the "what" of the service; functional quality is the "how."

23. What is the center line of a p-chart?
p-bar - the long-run percent defective.
Kaoru Ishikawa.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
X-bar-bar

24. Defect check sheets
Assigns scores to weighted criteria for each project under consideration.
Different types of defects are listed (used for Pareto chart)
Is what induces the failure
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

25. Based on what principal can we use the normal distribution assumptions for SPC?
Lean (or JIT).
Central Limit Theorem
To be a member of a Six Sigma project team.
The primary operating characteristics of a product.

26. FMEA
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Deming.
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
Define - measure - analyze - improve - control.

27. Design of Experiments (DOE) approach
Variable.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Linearity - normality - homoscedasticity - independence.
Attribute.

28. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Attribute
Different types of defects are listed (used for Pareto chart)
Pleasing to the senses.
3.4 (assuming 1.5 sigma shift in the mean)

29. Defect location check sheets
No -- only if the process is also capable.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Actual drawings - layouts - maps - etc which show where a defect occurs
The House of Quality.

30. List two components of internal failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Represents the behavior of a process
50%

31. Definition of Interaction
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Producer risk.
Pleasing to the senses.

32. Affinity Diagrams
Taguchi
QFD
Studying firms with the best performance in a particular area.
Organize ideas into meaningful categories by recognizing their underlying similarity

33. What are the four perspectives of the Balanced Scorecard?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Financial - customer - internal process - innovation and learning.
Someone who is consistently against virtually everything.

34. In a regression - what does R-square tell you?
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
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Critical to quality.

35. What do you do when a process is out of control?
To monitor a process when measurement by attribute is used.
Kaoru Ishikawa.
Financial - customer - internal process - innovation and learning.
Look for the assignable cause of non-random variation.

36. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Blame.
Hold all input variables constant except one. Observe the response as you vary the single input.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Outside.

37. Taguchi's experimental designs are of this type.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Hold all input variables constant except one. Observe the response as you vary the single input.
No -- only if the process is also capable.
Fractional factorial designs (orthogonal arrays)

38. Does it ever make sense to accept a job when a process is incapable?
Lower control limit.
Supplier - input - process - output - customer.
Define - measure - analyze - improve - control.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

39. For what is an x-bar chart used?
To monitor a process when measurement by variables is used.
Prevention - appraisal - internal failure - external failure.
Kaoru Ishikawa.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

40. What is written on the "spines" of a fishbone diagram?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Causes that lead to a particular effect.
The gap between what management thinks customers want and what customers really want.
Is what induces the failure

41. TWO-DIMENTIONAL SCATTER PLOT
68%
3.4 (assuming 1.5 sigma shift in the mean)
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Outside.

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

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43. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
The number of standard deviations some value is from the mean.
A tool that shows the physical flows through a space.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

44. What is the formula for the standard deviation of a proportion?
A tool that shows where there is waste in a process.
Different types of defects are listed (used for Pareto chart)
=sqrt((p*(1-p)/n)
Lean is waste reduction - Six Sigma is variation reduction.

45. What is the Baldrige Award?
Attribute.
Outside.
The US national quality award.
A brainstorming tool that shows the connections between ideas.

46. To what does the Six in Six Sigma relate?
Prevention - appraisal - internal failure - external failure.
Is the consequence of the failure.
Pleasing to the senses.
The target number of standard deviations from the mean for specifications.

47. One factor at a time (OFAT)
95%
Hold all input variables constant except one. Observe the response as you vary the single input.
It's good -- but it's still out of control!
Taguchi

48. In a regression - what does the standard error of the estimate tell you?
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.
Outside.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Defects Per Million Opportunities

49. Complete this quality phrase: 'Fix the process - not the _____.'
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Critical to quality.
Kaoru Ishikawa.
Blame.

50. Risk Priority Number RPN
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

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