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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.
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. Define performance quality.
50%
A tool that shows performance along key dimensions all at once.
The primary operating characteristics of a product.
99.73%

2. What is Jidoka?
Controlling quality at the source.
Is the consequence of the failure.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

3. What quality tool formally incorporates the voice of the customer?
QFD
Hold all input variables constant except one. Observe the response as you vary the single input.
Financial - customer - internal process - innovation and learning.
Mean time to replacement.

4. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
50%
Conformance to specifications.
A tool that shows performance along key dimensions all at once.
100%

5. What is Little's Law?
Inventory = throughput x flow time.
Fewer good units to sell - increased variable cost/unit.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
To obtain a certain desirable outcome from the process

6. Failure Mode
10 for Hazardous without warning 1 for none
Prevention - appraisal - internal failure - external failure.
Because the mean and standard deviation are independent of each other.
Is the way in which the failure is manifested.

7. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Consumer risk.
They move closer to the center line.
Lower skill requirements - faster - less chance for error.

8. List two components of external failure.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A descending order-sorted bar chart with a cumulative percentage line.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Shows the temporal flow of activities in a project network.

9. What is a spaghetti diagram?
To mentor/coach (and sometimes train) black belts.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
A tool that shows the physical flows through a space.
Defects Per Million Opportunities

10. In the Service Quality Gap Model - what is Gap 1?
The gap between what management thinks customers want and what customers really want.
A scatterplot.
No -- the variation also has to be random and "expected."
Observed variation in response is caused by the input

11. What happens to control limits on an SPC chart when sample size is increased?
Fishbone - cause-and-effect diagram.
95%
They move closer to the center line.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

12. What is a run chart?
Technical quality is the "what" of the service; functional quality is the "how."
No -- if it is not the same - it can only be worse!
A time series plot.
10 if Almost impossible to detect

13. Non-random patterns (Run Charts)
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Shifts - Trends - Repeating patterns - Correlation with known events
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

14. DFMEA
Inventory = throughput x flow time.
Initiated before or at design concept finalization
Mean time to replacement.
Supplier - input - process - output - customer.

15. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Actual drawings - layouts - maps - etc which show where a defect occurs
Conformance to specifications.
Sampling for SPC is done real time.
A time series plot.

16. Your production process meets customer specifications. Is your process in control?
Not necessarily.
A scatterplot.
Large enough to find two of the attribute - on average.
Prevention and appraisal costs are balanced against internal and external failure.

17. Test for constant variance
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
3.4 (assuming 1.5 sigma shift in the mean)
To mentor/coach (and sometimes train) black belts.
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.

18. In a regression - what does the p value of F tell you?
Sampling for SPC is done real time.
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).
Kaoru Ishikawa.
The ability of a process to consistently meet customer specifications.

19. Define takt time.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Inventory = throughput x flow time.
The cycle time required to meet demand.

20. What does a project prioritization matrix do?
They move closer to the center line.
Concluding there has been an effect/change when there has not.
Different types of defects are listed (used for Pareto chart)
Assigns scores to weighted criteria for each project under consideration.

21. Taguchi's experimental designs are of this type.
Hold all input variables constant except one. Observe the response as you vary the single input.
Fitness for use.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Fractional factorial designs (orthogonal arrays)

22. What is the 5S model?
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
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Observed variation in response is caused by the input

23. List two components of prevention cost.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
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
Supplier - input - process - output - customer.

24. Risk Priority Number RPN
Not necessarily.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The ability of a process to consistently meet customer specifications.
Method developed by Ishikawa to graphically display the causes of any given problem

25. What are two other names for an Ishikawa diagram?
Hold all input variables constant except one. Observe the response as you vary the single input.
Controlling quality at the source.
Fishbone - cause-and-effect diagram.
Supplier - input - process - output - customer.

26. Advantages of DOE
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
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
What the value of the dependent variable is when the independent variable is zero.
To mentor/coach (and sometimes train) black belts.

27. Detection Criteria Ranking
They move closer to the center line.
It looks to minimize the probability of a failure - or to minimize its effects
=sqrt(Σ(x-x-bar)^2)/(n-1))
10 if Almost impossible to detect

28. ANOVA

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29. In a Z table - what is Z?
The number of standard deviations some value is from the mean.
No -- the variation also has to be random and "expected."
Fishbone - cause-and-effect diagram.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

30. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
The target number of standard deviations from the mean for specifications.
68%
The House of Quality.
Outside.

31. Pareto Analysis
To monitor a process when measurement by variables is used.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Failure Modes and Effects Analysis
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

32. If you can only collect categorical data - what type of SPC charting can you do?
Attribute.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
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
Initiated before or at design concept finalization

33. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
The manager in charge of a process being improved in a Six Sigma project.
The gap between what management thinks customers want and what customers really want.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

34. Stratified defect check sheets
Assigns scores to weighted criteria for each project under consideration.
Stratify a particular defect type according to logical criteria
3.4 (assuming 1.5 sigma shift in the mean)
The gap between specifications and how service is performed.

35. What quality guru emphasizes management as a system?
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
QFD
Deming.
To do a capability study for a non-centered process.

36. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
68%
The gap between what customers expect and the service they receive.
Can't tell without a Range chart.
95%

37. What is the role of a green belt?
Walter A. Shewhart
A descending order-sorted bar chart with a cumulative percentage line.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
To be a member of a Six Sigma project team.

38. What do you do when a process is out of control?
10 if Almost impossible to detect
50%
Pleasing to the senses.
Look for the assignable cause of non-random variation.

39. Residual
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).
Speed - courtesy - competence - and ease of repair.
Financial - customer - internal process - innovation and learning.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

40. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Fewer good units to sell - increased variable cost/unit.
Financial - customer - internal process - innovation and learning.
Prevention and appraisal costs are balanced against internal and external failure.
Consumer risk.

41. In the Service Quality Gap Model - what is Gap 3?
To manage the Six Sigma project.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
The gap between specifications and how service is performed.
Different types of defects are listed (used for Pareto chart)

42. What does Crosby say about benchmarking?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
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
Attribute

43. Define serviceability.
0.9^3 or 72.9%
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Speed - courtesy - competence - and ease of repair.

44. What is DMADV?
Define - measure - analyze - design - verify.
Is the consequence of the failure.
To mentor/coach (and sometimes train) black belts.
Actual drawings - layouts - maps - etc which show where a defect occurs

45. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
The gap between what management thinks customers want and the process specifications.
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
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

46. Simple Regression Analysis (one factor regression model)
The Japanese national quality award.
= 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
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 process of ranking opportunities to determine which of many potential opportunities should be pursued first.

47. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Conformance to specifications.
The primary operating characteristics of a product.
Large enough to find two of the attribute - on average.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

48. If a Cp shows that a process is not capable - should you calculate Cpk?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
95%
Producer risk.
No -- if it is not the same - it can only be worse!

49. Manual Test for Nomality
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
10 if Almost impossible to detect
Walter A. Shewhart
Not necessarily.

50. When is Cpk used?
Waste.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
To do a capability study for a non-centered process.
What the value of the dependent variable is when the independent variable is zero.

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