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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. In the Service Quality Gap Model - what is Gap 3?
The gap between specifications and how service is performed.
No -- the variation also has to be random and "expected."
A scatterplot.
Define - measure - analyze - improve - control.

2. List two appraisal costs.
Pleasing to the senses.
Upper control limit.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
= 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

3. Process occurance ranking
To do a capability study for a non-centered process.
To monitor a process when measurement by attribute is used.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

4. What is the Baldrige Award?
The US national quality award.
Used to create frequency distribution tally sheets
Organize ideas into meaningful categories by recognizing their underlying similarity
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

5. Residual
Define - measure - analyze - design - verify.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Concluding there has not been an effect/change when there has.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

6. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Hold all input variables constant except one. Observe the response as you vary the single input.
Lower skill requirements - faster - less chance for error.
The secondary characteristics of a product; "bells and whistles."
Used to create frequency distribution tally sheets

7. What is the difference between Lean and Six Sigma?
The manager in charge of a process being improved in a Six Sigma project.
Prevention - appraisal - internal failure - external failure.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Lean is waste reduction - Six Sigma is variation reduction.

8. Your production process meets customer specifications. Is your process in control?
Brand image.
Prevention and appraisal costs are balanced against internal and external failure.
To obtain a certain desirable outcome from the process
Not necessarily.

9. Pareto Analysis
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The House of Quality.
The gap between what customers expect and the service they receive.
Scrap - rework - retest - downtime - yield losses - disposition costs.

10. What graphical tool is used to show the relationship between two numerical variables?
A tools that is used to measure the amount of variation in the measurement system arising from the measurement device (repeatability) and the people taking the measurement (reproducibility).
A scatterplot.
95%
The number of standard deviations some value is from the mean.

11. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
Define - measure - analyze - improve - control.
A tool that shows performance along key dimensions all at once.
Is the way in which the failure is manifested.

12. What are the 5 Ss?
Lower control limit.
Sort - Set in Order - Shine - Standardize - Sustain
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).
No -- the variation also has to be random and "expected."

13. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
No -- the variation also has to be random and "expected."
Define - measure - analyze - design - verify.
No -- only if the process is also capable.

14. What quality tool formally incorporates the voice of the customer?
Concluding there has not been an effect/change when there has.
The degree to which a product meets pre-established standards.
QFD
The gap between what management thinks customers want and what customers really want.

15. Detection Criteria Ranking
Financial - customer - internal process - innovation and learning.
A diagram that shows the relationships between activities in a project network.
5%
10 if Almost impossible to detect

16. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Attribute
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Through producer/consumer negotiation.
Conformance to specifications.

17. What percentage of a normal distribution lies above the mean?
50%
Before production starts
Variable.
Inventory = throughput x flow time.

18. What are the three main categories of assignable cause?
Represents the behavior of a process
3.4 (assuming 1.5 sigma shift in the mean)
Workers - machines - materials.
Studying firms with the best performance in a particular area.

19. Define performance quality.
No -- if it is not the same - it can only be worse!
A tool that shows where there is waste in a process.
The primary operating characteristics of a product.
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

20. How does Juran define quality?
Fitness for use.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Critical to quality.
The gap between specifications and how service is performed.

21. 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
Causes that lead to a particular effect.
A tool that shows where there is waste in a process.
The target number of standard deviations from the mean for specifications.

22. What is DPMO?
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
Lower skill requirements - faster - less chance for error.
Defects Per Million Opportunities
99.73%

23. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Producer risk.
Fishbone - cause-and-effect diagram.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Attribute

24. How are LQL and AQL determined in an acceptance sampling plan?
A diagram that shows the relationships between activities in a project network.
They move closer to the center line.
Taguchi
Through producer/consumer negotiation.

25. What is the center line of a p-chart?
Attribute
A random variable that summarizes the information from the sample(s).
p-bar - the long-run percent defective.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

26. Manual Test for Nomality
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
The gap between what management thinks customers want and what customers really want.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
They move closer to the center line.

27. Definition of Interaction
Deming.
Someone who is consistently against virtually everything.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
To manage the Six Sigma project.

28. What is a dashboard?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
0.9^3 or 72.9%
A tool that shows performance along key dimensions all at once.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

29. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Is the way in which the failure is manifested.
Lean (or JIT).
The gap between what management thinks customers want and the process specifications.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

30. Failure cause
A tool that shows where there is waste in a process.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Is what induces the failure
Attribute.

31. Design of Experiments (DOE) approach
Supplier - input - process - output - customer.
Stratify a particular defect type according to logical criteria
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Causes that lead to a particular effect.

32. In a Z table - what is Z?
The number of standard deviations some value is from the mean.
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!
Define - measure - analyze - design - verify.

33. FMEA
The US national quality award.
Attribute
Initiated before or at design concept finalization
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

34. What is process capability?
The ability of a process to consistently meet customer specifications.
Mistake-proofing.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Used to create frequency distribution tally sheets

35. Affinity Diagrams
Used to create frequency distribution tally sheets
The gap between what customers expect and the service they receive.
Kaoru Ishikawa.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

36. What is Kaizen?
Initiated before or at design concept finalization
Someone who is consistently against virtually everything.
Producer risk.
Rapid improvement process.

37. What is CTQ?
95%
Critical to quality.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

38. What does the abbreviation UCL stand for?
Fractional factorial designs (orthogonal arrays)
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Define - measure - analyze - design - verify.
Upper control limit.

39. What is a network diagram?
Variable.
A diagram that shows the relationships between activities in a project network.
Stratify a particular defect type according to logical criteria
A descending order-sorted bar chart with a cumulative percentage line.

40. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
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.
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
68%

41. TWO-DIMENTIONAL SCATTER PLOT
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
To manage the Six Sigma project.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

42. When yields decrease - what are the two effects on contribution?
Fewer good units to sell - increased variable cost/unit.
The secondary characteristics of a product; "bells and whistles."
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Causes that lead to a particular effect.

43. What is DMADV?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Define - measure - analyze - design - verify.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
To be a member of a Six Sigma project team.

44. Affinity Diagrams
The Japanese national quality award.
Used to create frequency distribution tally sheets
Financial - customer - internal process - innovation and learning.
Organize ideas into meaningful categories by recognizing their underlying similarity

45. Residual(eij)
= yij - y(bar)i --> value minus sum of that treatment (of row)
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
100%

46. With Six Sigma capability - how many defects per million opportunities would you see?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Observed variation in response is caused by the input
Someone who is consistently against virtually everything.
3.4 (assuming 1.5 sigma shift in the mean)

47. Simple Regression Analysis (one factor regression model)
Lower skill requirements - faster - less chance for error.
It's good -- but it's still out of control!
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
= 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

48. Risk Priority Number RPN
Lean is waste reduction - Six Sigma is variation reduction.
The gap between what management thinks customers want and what customers really want.
Brand image.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

49. What size should samples be for attribute SPC?
Can't tell without a Range chart.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Large enough to find two of the attribute - on average.
Define - measure - analyze - improve - control.

50. PFMEA
10 if Almost impossible to detect
Concluding there has been an effect/change when there has not.
Before production starts
No -- if it is not the same - it can only be worse!

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