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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. Your production process meets customer specifications. Is your process in control?
Not necessarily.
Different types of defects are listed (used for Pareto chart)
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Critical to quality.

2. Manual Test for Nomality
Studying firms with the best performance in a particular area.
Is the way in which the failure is manifested.
Rapid improvement process.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

3. What is DPMO?
Technical quality is the "what" of the service; functional quality is the "how."
Defects Per Million Opportunities
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).
The cycle time required to meet demand.

4. What are the Five Dimensions of Service Quality?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
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.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

5. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
The Japanese national quality award.
Organize ideas into meaningful categories by recognizing their underlying similarity
No -- the variation also has to be random and "expected."
Lean is waste reduction - Six Sigma is variation reduction.

6. In the Service Quality Gap Model - what is Gap 4?
The gap between what is promised and what is delivered.
Speed - courtesy - competence - and ease of repair.
95%
It's good -- but it's still out of control!

7. Which quality guru developed the concept of loss to society?
Stratify a particular defect type according to logical criteria
Taguchi
Variable.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

8. What type of risk is associated with Type II Error?
Represents the behavior of a process
Walter A. Shewhart
Consumer risk.
A descending order-sorted bar chart with a cumulative percentage line.

9. What is a Pareto chart?
A descending order-sorted bar chart with a cumulative percentage line.
To manage the Six Sigma project.
To do a capability study for a non-centered process.
Fractional factorial designs (orthogonal arrays)

10. Daniel Test
A tool that shows the physical flows through a space.
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:
Variable.
The gap between specifications and how service is performed.

11. What is CTQ?
To mentor/coach (and sometimes train) black belts.
Financial - customer - internal process - innovation and learning.
To obtain a certain desirable outcome from the process
Critical to quality.

12. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Method developed by Ishikawa to graphically display the causes of any given problem
Prevention and appraisal costs are balanced against internal and external failure.
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
Linearity - normality - homoscedasticity - independence.

13. Defect location check sheets
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
5%
Actual drawings - layouts - maps - etc which show where a defect occurs
A tool that shows performance along key dimensions all at once.

14. What is the formula for the standard deviation of a proportion?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Financial - customer - internal process - innovation and learning.
=sqrt((p*(1-p)/n)
Mean time to failure.

15. What is Kaizen?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Rapid improvement process.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Studying firms with the best performance in a particular area.

16. Failure cause
The US national quality award.
The gap between what is promised and what is delivered.
Used to create frequency distribution tally sheets
Is what induces the failure

17. What does SIPOC stand for?
Financial - customer - internal process - innovation and learning.
Pleasing to the senses.
A scatterplot.
Supplier - input - process - output - customer.

18. What is the Deming Prize?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
The Japanese national quality award.
Method developed by Ishikawa to graphically display the causes of any given problem
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

19. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Conformance to specifications.
Different types of defects are listed (used for Pareto chart)
Fractional factorial designs (orthogonal arrays)
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

20. What is the role of a master black belt?
Deming.
To mentor/coach (and sometimes train) black belts.
A random variable that summarizes the information from the sample(s).
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

21. Define conformance quality.
Pleasing to the senses.
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
= yij - y(bar)i --> value minus sum of that treatment (of row)
The degree to which a product meets pre-established standards.

22. To what does the Six in Six Sigma relate?
Variable.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
To monitor a process when measurement by attribute is used.
The target number of standard deviations from the mean for specifications.

23. List two components of prevention cost.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Taguchi
The manager in charge of a process being improved in a Six Sigma project.
Is what induces the failure

24. For what is an x-bar chart used?
To monitor a process when measurement by variables is used.
QFD
Pleasing to the senses.
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.

25. Statistical Hypothesis
Not necessarily.
Hold all input variables constant except one. Observe the response as you vary the single input.
The degree to which a product meets pre-established standards.
An assertion or conjecture concerning one or more populations

26. If a Cp shows that a process is not capable - should you calculate Cpk?
10 if Almost impossible to detect
Technical quality is the "what" of the service; functional quality is the "how."
No -- if it is not the same - it can only be worse!
The number of standard deviations some value is from the mean.

27. Regression
Lean (or JIT).
What the value of the dependent variable is when the independent variable is zero.
Represents the behavior of a process
Before production starts

28. If you have calculated a Cpk - should you also calculate a Cp?
The gap between specifications and how service is performed.
To manage the Six Sigma project.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Hold all input variables constant except one. Observe the response as you vary the single input.

29. What is Type 1 Error?
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
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
Concluding there has been an effect/change when there has not.

30. What percentage of a normal distribution lies above the mean?
Method developed by Ishikawa to graphically display the causes of any given problem
The cycle time required to meet demand.
The secondary characteristics of a product; "bells and whistles."
50%

31. Design of Experiments (DOE) approach
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Outside.
The manager in charge of a process being improved in a Six Sigma project.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

32. One factor at a time (OFAT)
The degree to which a product meets pre-established standards.
Lean is waste reduction - Six Sigma is variation reduction.
5%
Hold all input variables constant except one. Observe the response as you vary the single input.

33. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
68%
The US national quality award.
The ratio of outputs to inputs; 1-scrap.
A scatterplot.

34. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Lower skill requirements - faster - less chance for error.
They move closer to the center line.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

35. How does Juran define quality?
Prevention and appraisal costs are balanced against internal and external failure.
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:
Fitness for use.
=sqrt(Σ(x-x-bar)^2)/(n-1))

36. Who developed the fishbone diagram?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Kaoru Ishikawa.
Organize ideas into meaningful categories by recognizing their underlying similarity

37. Complete this quality phrase: 'Fix the process - not the _____.'
Is what induces the failure
=sqrt((p*(1-p)/n)
Blame.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

38. Which type of SPC measurement is more precise - variable or attribute?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
A brainstorming tool that shows the connections between ideas.
Variable.
Lower control limit.

39. Define benchmarking.
Rapid improvement process.
10 if Almost impossible to detect
Studying firms with the best performance in a particular area.
To obtain a certain desirable outcome from the process

40. What is the difference between Lean and Six Sigma?
Lean is waste reduction - Six Sigma is variation reduction.
Method developed by Ishikawa to graphically display the causes of any given problem
Concluding there has been an effect/change when there has not.
Technical quality is the "what" of the service; functional quality is the "how."

41. When yields decrease - what are the two effects on contribution?
Controlling quality at the source.
Fewer good units to sell - increased variable cost/unit.
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((p*(1-p)/n)

42. Name the structure associated with Quality Function Deployment.
The House of Quality.
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
Through producer/consumer negotiation.
To obtain a certain desirable outcome from the process

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

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44. What graphical tool is used to show the relationship between two numerical variables?
Mean time to failure.
Lower skill requirements - faster - less chance for error.
A scatterplot.
A tool that shows where there is waste in a process.

45. When is Cpk used?
To do a capability study for a non-centered process.
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:
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).
Concluding there has not been an effect/change when there has.

46. FMEA
Large enough to find two of the attribute - on average.
The gap between what customers expect and the service they receive.
Before production starts
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

47. What is the center line of an X-bar chart?
X-bar-bar
The gap between what is promised and what is delivered.
Organize ideas into meaningful categories by recognizing their underlying similarity
Rapid improvement process.

48. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
Technical quality is the "what" of the service; functional quality is the "how."
The degree to which a product meets pre-established standards.
To do a capability study for a non-centered process.

49. What is Little's Law?
Inventory = throughput x flow time.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Represents the behavior of a process
Through producer/consumer negotiation.

50. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
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
Inventory = throughput x flow time.

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Six Sigma

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