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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. If a three-stage process has 90% yields at each stage - what is the overall yield?
0.9^3 or 72.9%
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
Attribute
The gap between what is promised and what is delivered.

2. In the Service Quality Gap Model - what is Gap 2?
A tool that shows the physical flows through a space.
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
A tool that shows where there is waste in a process.
The gap between what management thinks customers want and the process specifications.

3. What is the Deming Prize?
Before production starts
A time series plot.
The Japanese national quality award.
A tool that shows where there is waste in a process.

4. In Juran's Cost of Quality model - which categories of costs balance which other categories?
To monitor a process when measurement by variables is used.
Someone who is consistently against virtually everything.
The gap between what management thinks customers want and the process specifications.
Prevention and appraisal costs are balanced against internal and external failure.

5. What is FMEA?
Failure Modes and Effects Analysis
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The secondary characteristics of a product; "bells and whistles."
Deming.

6. With Six Sigma capability - how many defects per million opportunities would you see?
3.4 (assuming 1.5 sigma shift in the mean)
The House of Quality.
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
To be a member of a Six Sigma project team.

7. Define performance quality.
Look for the assignable cause of non-random variation.
Initiated before or at design concept finalization
The primary operating characteristics of a product.
Inventory = throughput x flow time.

8. Advantages of DOE
Lean is waste reduction - Six Sigma is variation reduction.
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
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).
A time series plot.

9. Pareto Analysis
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
0.9^3 or 72.9%
Defects Per Million Opportunities
An assertion or conjecture concerning one or more populations

10. In a regression - what does the p value of F tell you?
Hold all input variables constant except one. Observe the response as you vary the single input.
Conformance to specifications.
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).
= yij - y(bar)i --> value minus sum of that treatment (of row)

11. Defect location check sheets
Variable.
Actual drawings - layouts - maps - etc which show where a defect occurs
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Stratify a particular defect type according to logical criteria

12. For what is an x-bar chart used?
Attribute.
Fewer good units to sell - increased variable cost/unit.
Through producer/consumer negotiation.
To monitor a process when measurement by variables is used.

13. What is Type 1 Error?
Outside.
Concluding there has been an effect/change when there has not.
Studying firms with the best performance in a particular area.
The gap between what management thinks customers want and what customers really want.

14. Failure cause
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
Is what induces the failure
50%
Studying firms with the best performance in a particular area.

15. Define features.
What the value of the dependent variable is when the independent variable is zero.
Initiated before or at design concept finalization
The secondary characteristics of a product; "bells and whistles."
Upper control limit.

16. What size should samples be for attribute SPC?
= yij - y(bar)i --> value minus sum of that treatment (of row)
100%
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.
Large enough to find two of the attribute - on average.

17. Which type of SPC measurement is more precise - variable or attribute?
Attribute.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Mean time to replacement.
Variable.

18. List two components of external failure.
Waste.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Speed - courtesy - competence - and ease of repair.

19. Non-random patterns (Run Charts)
Shifts - Trends - Repeating patterns - Correlation with known events
Lean (or JIT).
Used to create frequency distribution tally sheets
F_alpha - df(tr) - df (error)

20. What does a project prioritization matrix do?
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
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Linearity - normality - homoscedasticity - independence.
Assigns scores to weighted criteria for each project under consideration.

21. List two components of prevention cost.
= 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
Inventory = throughput x flow time.
The US national quality award.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

22. 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.
Variable.
A diagram that shows the relationships between activities in a project network.

23. What quality guru emphasizes management as a system?
95%
Fitness for use.
Deming.
False - because each machine will have different natural tolerances.

24. Define perceived quality (Garvin's framework).
Brand image.
A time series plot.
Stratify a particular defect type according to logical criteria
Lean is waste reduction - Six Sigma is variation reduction.

25. Cause and Effect Diagrams
Sort - Set in Order - Shine - Standardize - Sustain
Method developed by Ishikawa to graphically display the causes of any given problem
Studying firms with the best performance in a particular area.
Defects Per Million Opportunities

26. What is a run chart?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Shows the temporal flow of activities in a project network.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
A time series plot.

27. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Attribute
To do a capability study for a non-centered process.
Define - measure - analyze - design - verify.
Lower control limit.

28. What is a network diagram?
A diagram that shows the relationships between activities in a project network.
Someone who is consistently against virtually everything.
The Japanese national quality award.
What the value of the dependent variable is when the independent variable is zero.

29. Who is a process owner?
Linearity - normality - homoscedasticity - independence.
Central Limit Theorem
Reliability - Assurance - Responsiveness - Tangibles - Empathy
The manager in charge of a process being improved in a Six Sigma project.

30. Test for Independence
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
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).
Initiated before or at design concept finalization
Define - measure - analyze - improve - control.

31. Process check sheets
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Used to create frequency distribution tally sheets
Central Limit Theorem
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

32. What is the center line of a p-chart?
It looks to minimize the probability of a failure - or to minimize its effects
Consumer risk.
Central Limit Theorem
p-bar - the long-run percent defective.

33. What is a Gantt chart?
Shows the temporal flow of activities in a project network.
99.73%
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Defects Per Million Opportunities

34. What does DMAIC stand for?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Define - measure - analyze - improve - control.

35. Test for constant variance
Method developed by Ishikawa to graphically display the causes of any given problem
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.
Because the mean and standard deviation are independent of each other.
A time series plot.

36. Define benchmarking.
Studying firms with the best performance in a particular area.
Speed - courtesy - competence - and ease of repair.
The US 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

37. Effect ranking (Severity of the Defect)
99.73%
10 for Hazardous without warning 1 for none
The ability of a process to consistently meet customer specifications.
The Japanese national quality award.

38. Taguchi's experimental designs are of this type.
A tool that shows performance along key dimensions all at once.
Waste.
Fractional factorial designs (orthogonal arrays)
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).

39. What is the difference between the way sampling is done for SPC and for acceptance sampling?
The gap between what is promised and what is delivered.
Is the way in which the failure is manifested.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Sampling for SPC is done real time.

40. What is DMADV?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Variable.
Lean (or JIT).
Define - measure - analyze - design - verify.

41. Complete this quality phrase: 'Fix the process - not the _____.'
To manage the Six Sigma project.
False - because each machine will have different natural tolerances.
Blame.
Not necessarily.

42. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Lower skill requirements - faster - less chance for error.
Technical quality is the "what" of the service; functional quality is the "how."
68%
Method developed by Ishikawa to graphically display the causes of any given problem

43. What does SIPOC stand for?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Supplier - input - process - output - customer.
Used to create frequency distribution tally sheets
It looks to minimize the probability of a failure - or to minimize its effects

44. What is Jidoka?
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.
Fishbone - cause-and-effect diagram.
Controlling quality at the source.

45. When yields decrease - what are the two effects on contribution?
No -- if it is not the same - it can only be worse!
Walter A. Shewhart
Fewer good units to sell - increased variable cost/unit.
Hold all input variables constant except one. Observe the response as you vary the single input.

46. TWO-DIMENTIONAL SCATTER PLOT
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
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Large enough to find two of the attribute - on average.
Workers - machines - materials.

47. What quality tool formally incorporates the voice of the customer?
Mean time to replacement.
Is the way in which the failure is manifested.
QFD
To mentor/coach (and sometimes train) black belts.

48. What is the formula for the standard deviation of a proportion?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Shifts - Trends - Repeating patterns - Correlation with known events
Supplier - input - process - output - customer.
=sqrt((p*(1-p)/n)

49. In a regression - what does the coefficient of the intercept tell you
Rapid improvement process.
What the value of the dependent variable is when the independent variable is zero.
Because the mean and standard deviation are independent of each other.
Brand image.

50. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
68%
Define - measure - analyze - design - verify.
Lean (or JIT).
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

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