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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. List two components of prevention cost.
3.4 (assuming 1.5 sigma shift in the mean)
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Pleasing to the senses.
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

2. There are two milling machines in the shop. Data has been collected on one to compute control limits for both. This is acceptable SPC practice - true or false and why?
100%
False - because each machine will have different natural tolerances.
Taguchi
Central Limit Theorem

3. What are the four categories of costs in Juran's framework?
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
Prevention - appraisal - internal failure - external failure.
The gap between what management thinks customers want and the process specifications.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

4. Define takt time.
The cycle time required to meet demand.
Speed - courtesy - competence - and ease of repair.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Is what induces the failure

5. If you have calculated a Cpk - should you also calculate a Cp?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Shows the temporal flow of activities in a project network.
The House of Quality.
Waste.

6. Definition of Interaction
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:
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Is the way in which the failure is manifested.

7. Non-random patterns (Run Charts)
Workers - machines - materials.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Shifts - Trends - Repeating patterns - Correlation with known events
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:

8. List two components of external failure.
To monitor a process when measurement by attribute is used.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Observed variation in response is caused by the input
Represents the behavior of a process

9. List Garvin's eight dimensions of product quality.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
10 for Hazardous without warning 1 for none
Producer risk.
Assigns scores to weighted criteria for each project under consideration.

10. What is muda
The gap between specifications and how service is performed.
Sampling for SPC is done real time.
Pleasing to the senses.
Waste.

11. What is Jidoka?
Controlling quality at the source.
Lower control limit.
To monitor a process when measurement by variables is used.
Attribute.

12. Define durability.
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
Mean time to replacement.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
To monitor a process when measurement by variables is used.

13. How are LQL and AQL determined in an acceptance sampling plan?
The Japanese national quality award.
They move closer to the center line.
Shows the temporal flow of activities in a project network.
Through producer/consumer negotiation.

14. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
They move closer to the center line.
Lean is waste reduction - Six Sigma is variation reduction.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

15. What is the formula for the standard deviation of a proportion?
F_alpha - df(tr) - df (error)
50%
Kaoru Ishikawa.
=sqrt((p*(1-p)/n)

16. What is written on the "spines" of a fishbone diagram?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Lower control limit.
Causes that lead to a particular effect.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

17. Explain the difference between technical and functional service quality.
Is the consequence of the failure.
Technical quality is the "what" of the service; functional quality is the "how."
Stratify a particular defect type according to logical criteria
Look for the assignable cause of non-random variation.

18. Pareto Analysis
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
They move closer to the center line.
It looks to minimize the probability of a failure - or to minimize its effects
The degree to which a product meets pre-established standards.

19. How does Juran define quality?
=sqrt((p*(1-p)/n)
Mistake-proofing.
Fitness for use.
Different types of defects are listed (used for Pareto chart)

20. What is DPMO?
5%
A descending order-sorted bar chart with a cumulative percentage line.
Defects Per Million Opportunities
They move closer to the center line.

21. Effect ranking (Severity of the Defect)
Financial - customer - internal process - innovation and learning.
Shows the temporal flow of activities in a project network.
Fewer good units to sell - increased variable cost/unit.
10 for Hazardous without warning 1 for none

22. Process check sheets
Fractional factorial designs (orthogonal arrays)
Used to create frequency distribution tally sheets
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Attribute

23. Affinity Diagrams
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
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
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Someone who is consistently against virtually everything.

24. What does the abbreviation LCL stand for?
An assertion or conjecture concerning one or more populations
Workers - machines - materials.
Lower control limit.
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

25. Residual(eij)
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
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Concluding there has been an effect/change when there has not.
= yij - y(bar)i --> value minus sum of that treatment (of row)

26. What is the role of a master black belt?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
To mentor/coach (and sometimes train) black belts.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Technical quality is the "what" of the service; functional quality is the "how."

27. Your production process meets customer specifications. Is your process in control?
=sqrt(Σ(x-x-bar)^2)/(n-1))
Not necessarily.
Failure Modes and Effects Analysis
Lean (or JIT).

28. Who first studied randomness in industrial processes
Failure Modes and Effects Analysis
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Walter A. Shewhart
The ability of a process to consistently meet customer specifications.

29. With Six Sigma capability - how many defects per million opportunities would you see?
Someone who is consistently against virtually everything.
The secondary characteristics of a product; "bells and whistles."
3.4 (assuming 1.5 sigma shift in the mean)
The gap between what management thinks customers want and what customers really want.

30. Creating a Run Chart
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Different types of defects are listed (used for Pareto chart)
A time series plot.

31. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Prevention and appraisal costs are balanced against internal and external failure.
Causes that lead to a particular effect.
The US national quality award.

32. FMEA
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
=sqrt(Σ(x-x-bar)^2)/(n-1))
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
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

33. Design of Experiments (DOE) approach
Stratify a particular defect type according to logical criteria
Speed - courtesy - competence - and ease of repair.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
3.4 (assuming 1.5 sigma shift in the mean)

34. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The primary operating characteristics of a product.
5%
A descending order-sorted bar chart with a cumulative percentage line.

35. In a Z table - what is Z?
The number of standard deviations some value is from the mean.
Concluding there has been an effect/change when there has not.
Not necessarily.
Walter A. Shewhart

36. Advantages of DOE
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
Financial - customer - internal process - innovation and learning.
The gap between what is promised and what is delivered.
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

37. Define performance quality.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Lean is waste reduction - Six Sigma is variation reduction.
The primary operating characteristics of a product.

38. PFMEA
Before production starts
Look for the assignable cause of non-random variation.
Fishbone - cause-and-effect diagram.
No -- the variation also has to be random and "expected."

39. In a regression - what does R-square tell you?
Attribute
Speed - courtesy - competence - and ease of repair.
Rapid improvement process.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

40. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
Is the consequence of the failure.
The US national quality award.
A diagram that shows the relationships between activities in a project network.

41. What is poka yoke?
Mistake-proofing.
No -- only if the process is also capable.
Define - measure - analyze - improve - control.
Studying firms with the best performance in a particular area.

42. What is the difference between Lean and Six Sigma?
Initiated before or at design concept finalization
No -- the variation also has to be random and "expected."
=sqrt(Σ(x-x-bar)^2)/(n-1))
Lean is waste reduction - Six Sigma is variation reduction.

43. Define yield.
What the value of the dependent variable is when the independent variable is zero.
Represents the behavior of a process
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
The ratio of outputs to inputs; 1-scrap.

44. What are the four perspectives of the Balanced Scorecard?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Brand image.
Financial - customer - internal process - innovation and learning.
Fitness for use.

45. For what is a p-chart used?
Mean time to replacement.
No -- the variation also has to be random and "expected."
They move closer to the center line.
To monitor a process when measurement by attribute is used.

46. One factor at a time (OFAT)
Consumer risk.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
The primary operating characteristics of a product.
Observed variation in response is caused by the input

47. What are two other names for an Ishikawa diagram?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Lean is waste reduction - Six Sigma is variation reduction.
Fishbone - cause-and-effect diagram.
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. What does SIPOC stand for?
= 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.
Pleasing to the senses.
Supplier - input - process - output - customer.

49. What is a CAVE man?
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
Someone who is consistently against virtually everything.
A tool that shows the physical flows through a space.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

50. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
A brainstorming tool that shows the connections between ideas.
The Japanese national quality award.
Lower skill requirements - faster - less chance for error.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

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