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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. PFMEA
Lean is waste reduction - Six Sigma is variation reduction.
Can't tell without a Range chart.
Before production starts
Because the mean and standard deviation are independent of each other.

2. What is a network diagram?
A diagram that shows the relationships between activities in a project network.
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.
Upper control limit.
Consumer risk.

3. For what is a p-chart used?
To monitor a process when measurement by attribute is used.
Actual drawings - layouts - maps - etc which show where a defect occurs
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Concluding there has not been an effect/change when there has.

4. What quality tool formally incorporates the voice of the customer?
10 for Hazardous without warning 1 for none
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
QFD
The House of Quality.

5. ANOVA

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6. What does the abbreviation LCL stand for?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Represents the behavior of a process
Lower control limit.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

7. How does Juran define quality?
Fitness for use.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Define - measure - analyze - design - verify.
10 if Almost impossible to detect

8. 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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9. What is the role of a master black belt?
Conformance to specifications.
To mentor/coach (and sometimes train) black belts.
Supplier - input - process - output - customer.
A tool that shows performance along key dimensions all at once.

10. Based on what principal can we use the normal distribution assumptions for SPC?
Large enough to find two of the attribute - on average.
Central Limit Theorem
Stratify a particular defect type according to logical criteria
Producer risk.

11. Which quality guru developed the concept of loss to society?
Taguchi
Consumer risk.
Waste.
The gap between what management thinks customers want and what customers really want.

12. What is Kaizen?
Look for the assignable cause of non-random variation.
Taguchi
Outside.
Rapid improvement process.

13. What is Value Stream Mapping?
False - because each machine will have different natural tolerances.
Hold all input variables constant except one. Observe the response as you vary the single input.
A tool that shows where there is waste in a process.
The gap between what management thinks customers want and what customers really want.

14. What is Type II Error?
The ratio of outputs to inputs; 1-scrap.
Concluding there has not been an effect/change when there has.
No -- the variation also has to be random and "expected."
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:

15. Histogram by Hand
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
A scatterplot.
Variable.
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

16. Define takt time.
The cycle time required to meet demand.
A random variable that summarizes the information from the sample(s).
=sqrt(Σ(x-x-bar)^2)/(n-1))
It looks to minimize the probability of a failure - or to minimize its effects

17. Who developed the fishbone diagram?
Fewer good units to sell - increased variable cost/unit.
Failure Modes and Effects Analysis
Mean time to replacement.
Kaoru Ishikawa.

18. Residual(eij)
The cycle time required to meet demand.
Failure Modes and Effects Analysis
= yij - y(bar)i --> value minus sum of that treatment (of row)
The ratio of outputs to inputs; 1-scrap.

19. In the Service Quality Gap Model - what is Gap 4?
The gap between what is promised and what is delivered.
Lean (or JIT).
Method developed by Ishikawa to graphically display the causes of any given problem
A scatterplot.

20. Taguchi's experimental designs are of this type.
Linearity - normality - homoscedasticity - independence.
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
Lower control limit.

21. Affinity Diagrams
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Attribute.
Hold all input variables constant except one. Observe the response as you vary the single input.
Lean (or JIT).

22. What is the role of a green belt?
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.
Fishbone - cause-and-effect diagram.
Prevention - appraisal - internal failure - external failure.

23. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Conformance to specifications.
The gap between what is promised and what is delivered.
The manager in charge of a process being improved in a Six Sigma project.

24. Non-random patterns (Run Charts)
False - because each machine will have different natural tolerances.
Brand image.
The cycle time required to meet demand.
Shifts - Trends - Repeating patterns - Correlation with known events

25. Stratified defect check sheets
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
99.73%
Stratify a particular defect type according to logical criteria
F_alpha - df(tr) - df (error)

26. What is Type 1 Error?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Concluding there has been an effect/change when there has not.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The number of standard deviations some value is from the mean.

27. Why do you need two control charts for variables SPC?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Scrap - rework - retest - downtime - yield losses - disposition costs.
To be a member of a Six Sigma project team.
Because the mean and standard deviation are independent of each other.

28. What are the four perspectives of the Balanced Scorecard?
The target number of standard deviations from the mean for specifications.
Fractional factorial designs (orthogonal arrays)
Financial - customer - internal process - innovation and learning.
Through producer/consumer negotiation.

29. What is a Gantt chart?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
3.4 (assuming 1.5 sigma shift in the mean)
Shows the temporal flow of activities in a project network.

30. What are the 5 Ss?
To be a member of a Six Sigma project team.
Sort - Set in Order - Shine - Standardize - Sustain
Define - measure - analyze - design - verify.
A tool that shows the physical flows through a space.

31. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
No -- the variation also has to be random and "expected."
To obtain a certain desirable outcome from the process
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Variable.

32. What is DPMO?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Lower skill requirements - faster - less chance for error.
Defects Per Million Opportunities
Variable.

33. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Prevention and appraisal costs are balanced against internal and external failure.
Fewer good units to sell - increased variable cost/unit.
= 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
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).

34. Defect location check sheets
Actual drawings - layouts - maps - etc which show where a defect occurs
To mentor/coach (and sometimes train) black belts.
X-bar-bar
No -- if it is not the same - it can only be worse!

35. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Not necessarily.
Variable.
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

36. F value
F_alpha - df(tr) - df (error)
The ability of a process to consistently meet customer specifications.
No -- only if the process is also capable.
Producer risk.

37. FMEA
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
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
The ability of a process to consistently meet customer specifications.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

38. Advantages of DOE
Variable.
Lean (or JIT).
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
Different types of defects are listed (used for Pareto chart)

39. Define features.
The secondary characteristics of a product; "bells and whistles."
Concluding there has not been an effect/change when there has.
Lower control limit.
The degree to which a product meets pre-established standards.

40. What size should samples be for attribute SPC?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
The gap between what management thinks customers want and what customers really want.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Large enough to find two of the attribute - on average.

41. FMEA
Scrap - rework - retest - downtime - yield losses - disposition costs.
Because the mean and standard deviation are independent of each other.
Organize ideas into meaningful categories by recognizing their underlying similarity
It looks to minimize the probability of a failure - or to minimize its effects

42. In a regression - what does the coefficient of the intercept tell you
To monitor a process when measurement by attribute is used.
Sampling for SPC is done real time.
What the value of the dependent variable is when the independent variable is zero.
Kaoru Ishikawa.

43. Regression
Represents the behavior of a process
Taguchi
Sort - Set in Order - Shine - Standardize - Sustain
0.9^3 or 72.9%

44. List Garvin's eight dimensions of product quality.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Financial - customer - internal process - innovation and learning.
The gap between what management thinks customers want and what customers really want.
= 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

45. One factor at a time (OFAT)
To mentor/coach (and sometimes train) black belts.
95%
Hold all input variables constant except one. Observe the response as you vary the single input.
The gap between what management thinks customers want and what customers really want.

46. Disadvantages of DOE

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47. What does Crosby say about benchmarking?
10 if Almost impossible to detect
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
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

48. One factor at a time (OFAT)
Because the mean and standard deviation are independent of each other.
Initiated before or at design concept finalization
Used to create frequency distribution tally sheets
Observed variation in response is caused by the input

49. What is an affinity diagram?
A brainstorming tool that shows the connections between ideas.
A descending order-sorted bar chart with a cumulative percentage line.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
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).

50. Uses of regression - Control
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Organize ideas into meaningful categories by recognizing their underlying similarity
Stratify a particular defect type according to logical criteria
To obtain a certain desirable outcome from the process

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