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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. In the Service Quality Gap Model - what is Gap 2?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
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 gap between what management thinks customers want and the process specifications.
Define - measure - analyze - design - verify.

2. What type of risk is associated with Type 1 Error?
Producer risk.
The degree to which a product meets pre-established standards.
The secondary characteristics of a product; "bells and whistles."
To mentor/coach (and sometimes train) black belts.

3. If a three-stage process has 90% yields at each stage - what is the overall yield?
Consumer risk.
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
0.9^3 or 72.9%
Sampling for SPC is done real time.

4. What is Value Stream Mapping?
The number of standard deviations some value is from the mean.
A tool that shows where there is waste in a process.
3.4 (assuming 1.5 sigma shift in the mean)
A scatterplot.

5. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Concluding there has not been an effect/change when there has.
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).
Lean (or JIT).

6. What is DPMO?
The gap between what customers expect and the service they receive.
100%
Defects Per Million Opportunities
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

7. How does Juran define quality?
Sort - Set in Order - Shine - Standardize - Sustain
Taguchi
To monitor a process when measurement by variables is used.
Fitness for use.

8. What is muda
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
100%
Sampling for SPC is done real time.
Waste.

9. Who developed the fishbone diagram?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Stratify a particular defect type according to logical criteria
Define - measure - analyze - improve - control.
Kaoru Ishikawa.

10. Uses of regression - Control
The gap between what customers expect and the service they receive.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
To manage the Six Sigma project.
To obtain a certain desirable outcome from the process

11. List two appraisal costs.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Lean (or JIT).
Failure Modes and Effects Analysis
Workers - machines - materials.

12. In a regression - what does the coefficient of the intercept tell you
Lower control limit.
What the value of the dependent variable is when the independent variable is zero.
Mean time to failure.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

13. What is the role of a master black belt?
No -- only if the process is also capable.
To mentor/coach (and sometimes train) black belts.
Waste.
To be a member of a Six Sigma project team.

14. What does the abbreviation UCL stand for?
The number of standard deviations some value is from the mean.
Variable.
Upper control limit.
Fractional factorial designs (orthogonal arrays)

15. What are two other names for an Ishikawa diagram?
Concluding there has been an effect/change when there has not.
Controlling quality at the source.
It looks to minimize the probability of a failure - or to minimize its effects
Fishbone - cause-and-effect diagram.

16. What is the Baldrige Award?
The degree to which a product meets pre-established standards.
The US national quality award.
Concluding there has not been an effect/change when there has.
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

17. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Attribute
Workers - machines - materials.
The primary operating characteristics of a product.
Deming.

18. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
Workers - machines - materials.
Deming.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

19. Who is a process owner?
Fractional factorial designs (orthogonal arrays)
Fitness for use.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
The manager in charge of a process being improved in a Six Sigma project.

20. Explain the difference between technical and functional service quality.
Studying firms with the best performance in a particular area.
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
X-bar-bar
Technical quality is the "what" of the service; functional quality is the "how."

21. If a Cp shows that a process is not capable - should you calculate Cpk?
No -- if it is not the same - it can only be worse!
10 for Hazardous without warning 1 for none
Not necessarily.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

22. What are the three main categories of assignable cause?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
68%
Workers - machines - materials.
They move closer to the center line.

23. Detection Criteria Ranking
Variable.
Financial - customer - internal process - innovation and learning.
10 if Almost impossible to detect
Studying firms with the best performance in a particular area.

24. Why do you need two control charts for variables SPC?
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:
p-bar - the long-run percent defective.
Because the mean and standard deviation are independent of each other.

25. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Attribute.
To monitor a process when measurement by attribute is used.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Outside.

26. DFMEA
5%
Initiated before or at design concept finalization
100%
A tool that shows where there is waste in a process.

27. What is a histogram?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Workers - machines - materials.
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.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

28. What is Kaizen?
A brainstorming tool that shows the connections between ideas.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
No -- only if the process is also capable.
Rapid improvement process.

29. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Variable.
Sort - Set in Order - Shine - Standardize - Sustain

30. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Lean (or JIT).
False - because each machine will have different natural tolerances.
3.4 (assuming 1.5 sigma shift in the mean)
68%

31. One factor at a time (OFAT)
Fewer good units to sell - increased variable cost/unit.
It looks to minimize the probability of a failure - or to minimize its effects
To mentor/coach (and sometimes train) black belts.
Observed variation in response is caused by the input

32. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
Conformance to specifications.
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 simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

33. In the Service Quality Gap Model - what is Gap 1?
The gap between what management thinks customers want and what customers really want.
Attribute.
No -- the variation also has to be random and "expected."
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

34. What is a run chart?
A time series plot.
= 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
Sort - Set in Order - Shine - Standardize - Sustain
Different types of defects are listed (used for Pareto chart)

35. Your production process meets customer specifications. Is your process in control?
3.4 (assuming 1.5 sigma shift in the mean)
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Fitness for use.
Not necessarily.

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

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37. Pareto Analysis
Before production starts
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
99.73%
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

38. List two components of internal failure.
Upper control limit.
Scrap - rework - retest - downtime - yield losses - disposition costs.
p-bar - the long-run percent defective.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

39. Define yield.
Variable.
The target number of standard deviations from the mean for specifications.
The ratio of outputs to inputs; 1-scrap.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

40. If you have calculated a Cpk - should you also calculate a Cp?
10 if Almost impossible to detect
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Define - measure - analyze - improve - control.

41. What is the Deming Prize?
The Japanese national quality award.
10 for Hazardous without warning 1 for none
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Linearity - normality - homoscedasticity - independence.

42. ANOVA

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43. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Variable.
99.73%
A scatterplot.
5%

44. Cause and Effect Diagrams
Can't tell without a Range chart.
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
=sqrt((p*(1-p)/n)
Method developed by Ishikawa to graphically display the causes of any given problem

45. Define durability.
Blame.
Mean time to replacement.
Hold all input variables constant except one. Observe the response as you vary the single input.
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

46. Creating a Run Chart
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Pleasing to the senses.
Controlling quality at the source.
A tool that shows where there is waste in a process.

47. Regression
Used to create frequency distribution tally sheets
Represents the behavior of a process
Workers - machines - materials.
Prevention and appraisal costs are balanced against internal and external failure.

48. Residual
QFD
Fitness for use.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Lower skill requirements - faster - less chance for error.

49. What quality tool formally incorporates the voice of the customer?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
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
QFD

50. Define aesthetic quality.
Technical quality is the "what" of the service; functional quality is the "how."
Pleasing to the senses.
Deming.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

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