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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. Regression
False - because each machine will have different natural tolerances.
Variable.
100%
Represents the behavior of a process

2. Define performance quality.
The primary operating characteristics of a product.
The gap between specifications and how service is performed.
Central Limit Theorem
Critical to quality.

3. Histogram by Hand
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
A diagram that shows the relationships between activities in a project network.
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

4. What does the abbreviation LCL stand for?
Mistake-proofing.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Lower control limit.

5. What is DMADV?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Define - measure - analyze - design - verify.
Mean time to failure.
Concluding there has not been an effect/change when there has.

6. Detection Criteria Ranking
10 if Almost impossible to detect
The cycle time required to meet demand.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
A time series plot.

7. PFMEA
Observed variation in response is caused by the input
Shifts - Trends - Repeating patterns - Correlation with known events
Before production starts
A time series plot.

8. In the Service Quality Gap Model - what is Gap 2?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
X-bar-bar
Lower control limit.
The gap between what management thinks customers want and the process specifications.

9. What are two other names for an Ishikawa diagram?
99.73%
Fewer good units to sell - increased variable cost/unit.
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
Fishbone - cause-and-effect diagram.

10. Defect location check sheets
Actual drawings - layouts - maps - etc which show where a defect occurs
Before production starts
3.4 (assuming 1.5 sigma shift in the mean)
Lean is waste reduction - Six Sigma is variation reduction.

11. If you can only collect categorical data - what type of SPC charting can you do?
A diagram that shows the relationships between activities in a project network.
10 for Hazardous without warning 1 for none
Variable.
Attribute.

12. What type of risk is associated with Type II Error?
Consumer risk.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Deming.
3.4 (assuming 1.5 sigma shift in the mean)

13. What is CTQ?
Critical to quality.
Through producer/consumer negotiation.
Upper control limit.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

14. Define yield.
The House of Quality.
The cycle time required to meet demand.
Is what induces the failure
The ratio of outputs to inputs; 1-scrap.

15. What do you do when a process is out of control?
Waste.
Look for the assignable cause of non-random variation.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Stratify a particular defect type according to logical criteria

16. What is poka yoke?
Mistake-proofing.
To manage the Six Sigma project.
Concluding there has not been an effect/change when there has.
Is the consequence of the failure.

17. What is the Baldrige Award?
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The US national quality award.
Initiated before or at design concept finalization
Organize ideas into meaningful categories by recognizing their underlying similarity

18. What is Little's Law?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
The primary operating characteristics of a product.
Linearity - normality - homoscedasticity - independence.
Inventory = throughput x flow time.

19. Stratified defect check sheets
Taguchi
Stratify a particular defect type according to logical criteria
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 tool that shows where there is waste in a process.

20. What is the difference between Lean and Six Sigma?
Before production starts
Lean is waste reduction - Six Sigma is variation reduction.
0.9^3 or 72.9%
X-bar-bar

21. Residual
Blame.
The primary operating characteristics of a product.
The gap between what is promised and what is delivered.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

22. Defect check sheets
Different types of defects are listed (used for Pareto chart)
Brand image.
Sort - Set in Order - Shine - Standardize - Sustain
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

23. What is DPMO?
The secondary characteristics of a product; "bells and whistles."
Fractional factorial designs (orthogonal arrays)
Defects Per Million Opportunities
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

24. What does DMAIC stand for?
Define - measure - analyze - improve - control.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The primary operating characteristics of a product.
Stratify a particular defect type according to logical criteria

25. In a regression - what does the standard error of the estimate tell you?
=sqrt(Σ(x-x-bar)^2)/(n-1))
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Stratify a particular defect type according to logical criteria
10 if Almost impossible to detect

26. Who is a process owner?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
An assertion or conjecture concerning one or more populations
Kaoru Ishikawa.
The manager in charge of a process being improved in a Six Sigma project.

27. List two components of prevention cost.
Fitness for use.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
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).

28. When is Cpk used?
To do a capability study for a non-centered process.
It's good -- but it's still out of control!
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Brand image.

29. What is a Gage R&R?
To do a capability study for a non-centered process.
Different types of defects are listed (used for Pareto chart)
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 descending order-sorted bar chart with a cumulative percentage line.

30. Uses of regression - Control
To obtain a certain desirable outcome from the process
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.
A tool that shows the physical flows through a space.

31. Define benchmarking.
Speed - courtesy - competence - and ease of repair.
Initiated before or at design concept finalization
3.4 (assuming 1.5 sigma shift in the mean)
Studying firms with the best performance in a particular area.

32. TWO-DIMENTIONAL SCATTER PLOT
Defects Per Million Opportunities
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
X-bar-bar
Speed - courtesy - competence - and ease of repair.

33. Complete this quality phrase: 'Fix the process - not the _____.'
Prevention - appraisal - internal failure - external failure.
Rapid improvement process.
Blame.
Fishbone - cause-and-effect diagram.

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. What quality guru emphasizes management as a system?
Before production starts
Deming.
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:
Walter A. Shewhart

36. Process occurance ranking
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The target number of standard deviations from the mean for specifications.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

37. Design of Experiments (DOE) approach
Before production starts
Fitness for use.
Outside.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

38. List two components of external failure.
Workers - machines - materials.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Through producer/consumer negotiation.
Financial - customer - internal process - innovation and learning.

39. What is Value Stream Mapping?
Conformance to specifications.
To monitor a process when measurement by variables is used.
To manage the Six Sigma project.
A tool that shows where there is waste in a process.

40. A process is operating "in control." Does this mean the customer's requirements are met?
No -- only if the process is also capable.
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
Critical to quality.
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:

41. Creating a Run Chart
Technical quality is the "what" of the service; functional quality is the "how."
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Producer risk.
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

42. In the Service Quality Gap Model - what is Gap 5?
Lean is waste reduction - Six Sigma is variation reduction.
A random variable that summarizes the information from the sample(s).
Attribute.
The gap between what customers expect and the service they receive.

43. What are the four categories of costs in Juran's framework?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Prevention - appraisal - internal failure - external failure.
68%
The target number of standard deviations from the mean for specifications.

44. In Juran's Cost of Quality model - which categories of costs balance which other categories?
The degree to which a product meets pre-established standards.
Prevention and appraisal costs are balanced against internal and external failure.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Attribute

45. Why do you need two control charts for variables SPC?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
No -- only if the process is also capable.
Because the mean and standard deviation are independent of each other.
Rapid improvement process.

46. Explain the difference between technical and functional service quality.
Technical quality is the "what" of the service; functional quality is the "how."
Different types of defects are listed (used for Pareto chart)
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 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

47. Advantages of DOE
The gap between what customers expect and the service they receive.
Rapid improvement process.
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
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

48. Affinity Diagrams
Organize ideas into meaningful categories by recognizing their underlying similarity
0.9^3 or 72.9%
Define - measure - analyze - improve - control.
What the value of the dependent variable is when the independent variable is zero.

49. What are the Five Dimensions of Service Quality?
Producer risk.
Kaoru Ishikawa.
Technical quality is the "what" of the service; functional quality is the "how."
Reliability - Assurance - Responsiveness - Tangibles - Empathy

50. Define serviceability.
Speed - courtesy - competence - and ease of repair.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
10 if Almost impossible to detect
Variable.

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