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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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1. Creating a Run Chart
It looks to minimize the probability of a failure - or to minimize its effects
To obtain a certain desirable outcome from the process
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
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).

2. Test for Independence
Observed variation in response is caused by the input
The target number of standard deviations from the mean for specifications.
A random variable that summarizes the information from the sample(s).
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

3. 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?
=sqrt((p*(1-p)/n)
Shifts - Trends - Repeating patterns - Correlation with known events
Not necessarily.
False - because each machine will have different natural tolerances.

4. What are two other names for an Ishikawa diagram?
Fishbone - cause-and-effect diagram.
Fitness for use.
Through producer/consumer negotiation.
0.9^3 or 72.9%

5. Define takt time.
To obtain a certain desirable outcome from the process
The gap between what management thinks customers want and what customers really want.
The cycle time required to meet demand.
Assigns scores to weighted criteria for each project under consideration.

6. Residual(eij)
Central Limit Theorem
Rapid improvement process.
Attribute.
= yij - y(bar)i --> value minus sum of that treatment (of row)

7. What is a CAVE man?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Failure Modes and Effects Analysis
Prevention and appraisal costs are balanced against internal and external failure.
Someone who is consistently against virtually everything.

8. Design of Experiments (DOE) approach
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Mean time to failure.
Used to create frequency distribution tally sheets

9. F value
The gap between what is promised and what is delivered.
F_alpha - df(tr) - df (error)
Initiated before or at design concept finalization
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

10. What is a network diagram?
A diagram that shows the relationships between activities in a project network.
A descending order-sorted bar chart with a cumulative percentage line.
Method developed by Ishikawa to graphically display the causes of any given problem
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

11. What is the center line of an X-bar chart?
X-bar-bar
99.73%
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

12. What does the abbreviation UCL stand for?
3.4 (assuming 1.5 sigma shift in the mean)
Inventory = throughput x flow time.
To manage the Six Sigma project.
Upper control limit.

13. What do you do when a process is out of control?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Look for the assignable cause of non-random variation.
Variable.
Different types of defects are listed (used for Pareto chart)

14. List two components of internal failure.
95%
No -- the variation also has to be random and "expected."
= 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
Scrap - rework - retest - downtime - yield losses - disposition costs.

15. List Garvin's eight dimensions of product quality.
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).
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Causes that lead to a particular effect.
3.4 (assuming 1.5 sigma shift in the mean)

16. What is the formula for standard deviation?
Workers - machines - materials.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
=sqrt(Σ(x-x-bar)^2)/(n-1))

17. Failure Mode
Is the way in which the failure is manifested.
They move closer to the center line.
0.9^3 or 72.9%
Brand image.

18. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Lower skill requirements - faster - less chance for error.
Supplier - input - process - output - customer.
Outside.
Fractional factorial designs (orthogonal arrays)

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

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20. PFMEA
Observed variation in response is caused by the input
=sqrt((p*(1-p)/n)
50%
Before production starts

21. What is a Pareto chart?
Mean time to replacement.
A descending order-sorted bar chart with a cumulative percentage line.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
They move closer to the center line.

22. What is Value Stream Mapping?
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
A tool that shows where there is waste in a process.
It's good -- but it's still out of control!
The gap between what management thinks customers want and what customers really want.

23. What is the Deming Prize?
The Japanese national quality award.
Workers - machines - materials.
A tool that shows performance along key dimensions all at once.
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

24. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
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
95%
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:

25. For what is a p-chart used?
Fitness for use.
A scatterplot.
To monitor a process when measurement by attribute is used.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

26. Failure effect
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Through producer/consumer negotiation.
Is the consequence of the failure.
= 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

27. What is the center line of a p-chart?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The target number of standard deviations from the mean for specifications.
No -- the variation also has to be random and "expected."
p-bar - the long-run percent defective.

28. You have been plotting sample means on an x-bar chart and all points indicate normal - expected variation. Is the process in control?

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29. ANOVA

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30. Histogram by Hand
Fractional factorial designs (orthogonal arrays)
Fitness for use.
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
Lean is waste reduction - Six Sigma is variation reduction.

31. DFMEA
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Initiated before or at design concept finalization
Used to create frequency distribution tally sheets
Producer risk.

32. What quality tool formally incorporates the voice of the customer?
Shows the temporal flow of activities in a project network.
The ability of a process to consistently meet customer specifications.
=sqrt((p*(1-p)/n)
QFD

33. What is the role of a black belt?
Outside.
The primary operating characteristics of a product.
To manage the Six Sigma project.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

34. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
Central Limit Theorem
68%
Define - measure - analyze - design - verify.

35. What is Jidoka?
Brand image.
Lean is waste reduction - Six Sigma is variation reduction.
Controlling quality at the source.
To monitor a process when measurement by attribute is used.

36. What is DPMO?
Not necessarily.
Defects Per Million Opportunities
Technical quality is the "what" of the service; functional quality is the "how."
95%

37. What size should samples be for attribute SPC?
Large enough to find two of the attribute - on average.
Outside.
Is the consequence of the failure.
The ratio of outputs to inputs; 1-scrap.

38. In the Service Quality Gap Model - what is Gap 5?
Lean (or JIT).
Observed variation in response is caused by the input
The gap between what customers expect and the service they receive.
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

39. What type of risk is associated with Type II Error?
Attribute
The number of standard deviations some value is from the mean.
Lean (or JIT).
Consumer risk.

40. What is Type 1 Error?
Concluding there has been an effect/change when there has not.
Sort - Set in Order - Shine - Standardize - Sustain
10 for Hazardous without warning 1 for none
A brainstorming tool that shows the connections between ideas.

41. What graphical tool is used to show the relationship between two numerical variables?
A scatterplot.
50%
Inventory = throughput x flow time.
Consumer risk.

42. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
68%
The secondary characteristics of a product; "bells and whistles."
A scatterplot.
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

43. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Sampling for SPC is done real time.
Can't tell without a Range chart.
The ratio of outputs to inputs; 1-scrap.
Speed - courtesy - competence - and ease of repair.

44. What are the four categories of costs in Juran's framework?
Prevention - appraisal - internal failure - external failure.
The manager in charge of a process being improved in a Six Sigma project.
Concluding there has been an effect/change when there has not.
Waste.

45. What is the role of a green belt?
Critical to quality.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
To be a member of a Six Sigma project team.

46. Which quality guru developed the concept of loss to society?
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
An assertion or conjecture concerning one or more populations
Taguchi
95%

47. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
False - because each machine will have different natural tolerances.
Blame.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Lean (or JIT).

48. What is the 5S model?
Blame.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Consumer risk.
Prevention - appraisal - internal failure - external failure.

49. When yields decrease - what are the two effects on contribution?
Fewer good units to sell - increased variable cost/unit.
Attribute.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
To be a member of a Six Sigma project team.

50. What is a histogram?
Not necessarily.
100%
The ratio of outputs to inputs; 1-scrap.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

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Six Sigma

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