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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. What does DMAIC stand for?
Variable.
The gap between what is promised and what is delivered.
Pleasing to the senses.
Define - measure - analyze - improve - control.

2. A process is operating "in control." Does this mean the customer's requirements are met?
No -- only if the process is also capable.
Concluding there has not been an effect/change when there has.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Shows the temporal flow of activities in a project network.

3. What is process capability?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Scrap - rework - retest - downtime - yield losses - disposition costs.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The ability of a process to consistently meet customer specifications.

4. How are LQL and AQL determined in an acceptance sampling plan?
Is what induces the failure
Fitness for use.
Through producer/consumer negotiation.
The gap between what management thinks customers want and the process specifications.

5. Creating a Run Chart
Through producer/consumer negotiation.
Not necessarily.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

6. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
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.
Failure Modes and Effects Analysis
Mean time to replacement.

7. In a Z table - what is Z?
Variable.
Prevention - appraisal - internal failure - external failure.
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

8. Define product reliability.
Mean time to failure.
Lean is waste reduction - Six Sigma is variation reduction.
The gap between specifications and how service is performed.
Brand image.

9. What is Value Stream Mapping?
A tool that shows where there is waste in a process.
X-bar-bar
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.

10. Who is a process owner?
The gap between what customers expect and the service they receive.
The gap between what management thinks customers want and the process specifications.
The manager in charge of a process being improved in a Six Sigma project.
Actual drawings - layouts - maps - etc which show where a defect occurs

11. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Outside.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
10 if Almost impossible to detect
Upper control limit.

12. Affinity Diagrams
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Scrap - rework - retest - downtime - yield losses - disposition costs.
Stratify a particular defect type according to logical criteria

13. PFMEA
Before production starts
Technical quality is the "what" of the service; functional quality is the "how."
To do a capability study for a non-centered process.
Someone who is consistently against virtually everything.

14. Process occurance ranking
Outside.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Fishbone - cause-and-effect diagram.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

15. In the Service Quality Gap Model - what is Gap 2?
Someone who is consistently against virtually everything.
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
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The gap between what management thinks customers want and the process specifications.

16. If a three-stage process has 90% yields at each stage - what is the overall yield?
Central Limit Theorem
It's good -- but it's still out of control!
0.9^3 or 72.9%
Supplier - input - process - output - customer.

17. What is Jidoka?
Linearity - normality - homoscedasticity - independence.
The gap between what management thinks customers want and what customers really want.
Pleasing to the senses.
Controlling quality at the source.

18. With Six Sigma capability - how many defects per million opportunities would you see?
The House of Quality.
The primary operating characteristics of a product.
Fishbone - cause-and-effect diagram.
3.4 (assuming 1.5 sigma shift in the mean)

19. What is the center line of a p-chart?
p-bar - the long-run percent defective.
A diagram that shows the relationships between activities in a project network.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
= 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

20. What is CTQ?
Critical to quality.
68%
= yij - y(bar)i --> value minus sum of that treatment (of row)
Initiated before or at design concept finalization

21. For what is a p-chart used?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Lean (or JIT).
Scrap - rework - retest - downtime - yield losses - disposition costs.
To monitor a process when measurement by attribute is used.

22. Why do you need two control charts for variables SPC?
Define - measure - analyze - design - verify.
Prevention - appraisal - internal failure - external failure.
Because the mean and standard deviation are independent of each other.
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

23. Taguchi's experimental designs are of this type.
p-bar - the long-run percent defective.
Critical to quality.
Fractional factorial designs (orthogonal arrays)
Different types of defects are listed (used for Pareto chart)

24. What are two other names for an Ishikawa diagram?
A brainstorming tool that shows the connections between ideas.
Fishbone - cause-and-effect diagram.
Shifts - Trends - Repeating patterns - Correlation with known events
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

25. Effect ranking (Severity of the Defect)
= 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
68%
10 for Hazardous without warning 1 for none
To monitor a process when measurement by variables is used.

26. One factor at a time (OFAT)
Prevention and appraisal costs are balanced against internal and external failure.
No -- only if the process is also capable.
Large enough to find two of the attribute - on average.
Hold all input variables constant except one. Observe the response as you vary the single input.

27. FMEA
A scatterplot.
100%
The cycle time required to meet demand.
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

28. Uses of regression
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Shows the temporal flow of activities in a project network.
A random variable that summarizes the information from the sample(s).
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

29. What is the center line of an X-bar chart?
Inventory = throughput x flow time.
Large enough to find two of the attribute - on average.
X-bar-bar
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

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

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31. Disadvantages of DOE

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32. Process check sheets
Used to create frequency distribution tally sheets
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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:
The gap between what management thinks customers want and what customers really want.

33. List two appraisal costs.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Waste.
Blame.

34. TWO-DIMENTIONAL SCATTER PLOT
Through producer/consumer negotiation.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
It looks to minimize the probability of a failure - or to minimize its effects
Linearity - normality - homoscedasticity - independence.

35. What are the four regression assumptions?
Method developed by Ishikawa to graphically display the causes of any given problem
Linearity - normality - homoscedasticity - independence.
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
It looks to minimize the probability of a failure - or to minimize its effects

36. If a Cp shows that a process is not capable - should you calculate Cpk?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Observed variation in response is caused by the input
No -- if it is not the same - it can only be worse!
Fractional factorial designs (orthogonal arrays)

37. What is the role of a black belt?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
To manage the Six Sigma project.
Mean time to replacement.
95%

38. What is DPMO?
Defects Per Million Opportunities
The secondary characteristics of a product; "bells and whistles."
Actual drawings - layouts - maps - etc which show where a defect occurs
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

39. Statistical Hypothesis
Someone who is consistently against virtually everything.
The number of standard deviations some value is from the mean.
An assertion or conjecture concerning one or more populations
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

40. What graphical tool is used to show the relationship between two numerical variables?
A scatterplot.
Concluding there has not been an effect/change when there has.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
= 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

41. What does Crosby say about benchmarking?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
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:
Concluding there has not been an effect/change when there has.
Not necessarily.

42. Affinity Diagrams
If the Response vs. Levels graph if the response lines are not parallel (crossing)
False - because each machine will have different natural tolerances.
Organize ideas into meaningful categories by recognizing their underlying similarity
Reliability - Assurance - Responsiveness - Tangibles - Empathy

43. Complete this quality phrase: 'Fix the process - not the _____.'
95%
Before production starts
The number of standard deviations some value is from the mean.
Blame.

44. In the Service Quality Gap Model - what is Gap 3?
Defects Per Million Opportunities
The gap between specifications and how service is performed.
Causes that lead to a particular effect.
Taguchi

45. Your production process meets customer specifications. Is your process in control?
Not necessarily.
Because the mean and standard deviation are independent of each other.
Prevention and appraisal costs are balanced against internal and external failure.
A descending order-sorted bar chart with a cumulative percentage line.

46. Define serviceability.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Speed - courtesy - competence - and ease of repair.
Taguchi

47. What type of risk is associated with Type 1 Error?
Fractional factorial designs (orthogonal arrays)
= yij - y(bar)i --> value minus sum of that treatment (of row)
Producer risk.
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

48. What are the four categories of costs in Juran's framework?
100%
10 for Hazardous without warning 1 for none
Prevention - appraisal - internal failure - external failure.
Financial - customer - internal process - innovation and learning.

49. Residual(eij)
Can't tell without a Range chart.
Concluding there has not been an effect/change when there has.
To monitor a process when measurement by variables is used.
= yij - y(bar)i --> value minus sum of that treatment (of row)

50. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Waste.
=sqrt((p*(1-p)/n)
Attribute
The degree to which a product meets pre-established standards.

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