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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. TWO-DIMENTIONAL SCATTER PLOT
Look for the assignable cause of non-random variation.
Observed variation in response is caused by the input
False - because each machine will have different natural tolerances.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

2. Define aesthetic quality.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
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
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
Pleasing to the senses.

3. What is muda
Kaoru Ishikawa.
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:
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
Waste.

4. Affinity Diagrams
The House of Quality.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Actual drawings - layouts - maps - etc which show where a defect occurs
Organize ideas into meaningful categories by recognizing their underlying similarity

5. In a regression - what does the p value of F tell you?
Variable.
Lean is waste reduction - Six Sigma is variation reduction.
Mean time to failure.
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).

6. If you can only collect categorical data - what type of SPC charting can you do?
Different types of defects are listed (used for Pareto chart)
Sort - Set in Order - Shine - Standardize - Sustain
Deming.
Attribute.

7. What is a Gantt chart?
Deming.
The US national quality award.
Hold all input variables constant except one. Observe the response as you vary the single input.
Shows the temporal flow of activities in a project network.

8. Presence of interaction effect
Before production starts
The degree to which a product meets pre-established standards.
A tool that shows the physical flows through a space.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

9. What are the four regression assumptions?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Linearity - normality - homoscedasticity - independence.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Lean (or JIT).

10. What size should samples be for attribute SPC?
Large enough to find two of the attribute - on average.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Rapid improvement process.
10 if Almost impossible to detect

11. Creating a Run Chart
No -- if it is not the same - it can only be worse!
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Can't tell without a Range chart.
Large enough to find two of the attribute - on average.

12. DOE
50%
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Critical to quality.
=sqrt(Σ(x-x-bar)^2)/(n-1))

13. Daniel Test
Scrap - rework - retest - downtime - yield losses - disposition costs.
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:
Inventory = throughput x flow time.
Large enough to find two of the attribute - on average.

14. Manual Test for Nomality
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
The primary operating characteristics of a product.
Before production starts
Because the mean and standard deviation are independent of each other.

15. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
=sqrt((p*(1-p)/n)
Lean (or JIT).
Inventory = throughput x flow time.
The gap between specifications and how service is performed.

16. For what is a p-chart used?
To monitor a process when measurement by attribute is used.
Speed - courtesy - competence - and ease of repair.
Central Limit Theorem
A scatterplot.

17. Define yield.
= yij - y(bar)i --> value minus sum of that treatment (of row)
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The ratio of outputs to inputs; 1-scrap.
Speed - courtesy - competence - and ease of repair.

18. Risk Priority Number RPN
A random variable that summarizes the information from the sample(s).
Is what induces the failure
The cycle time required to meet demand.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

19. What is the role of a master black belt?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
To mentor/coach (and sometimes train) black belts.
Kaoru Ishikawa.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

20. Disadvantages of DOE

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21. Which type of SPC measurement is more precise - variable or attribute?
Variable.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
The cycle time required to meet demand.
Walter A. Shewhart

22. What does Crosby say about benchmarking?
No -- only if the process is also capable.
The gap between what management thinks customers want and the process specifications.
Different types of defects are listed (used for Pareto chart)
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

23. What is the Baldrige Award?
Look for the assignable cause of non-random variation.
The US national quality award.
Observed variation in response is caused by the input
Conformance to specifications.

24. What percentage of a normal distribution lies above the mean?
50%
Blame.
Producer risk.
Pleasing to the senses.

25. What is a histogram?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
A tool that shows the physical flows through a space.
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
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

26. Complete this quality phrase: 'Fix the process - not the _____.'
Blame.
Sort - Set in Order - Shine - Standardize - Sustain
Lean (or JIT).
Before production starts

27. List two appraisal costs.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
What the value of the dependent variable is when the independent variable is zero.
= yij - y(bar)i --> value minus sum of that treatment (of row)
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

28. What is Little's Law?
=sqrt((p*(1-p)/n)
Used to create frequency distribution tally sheets
Studying firms with the best performance in a particular area.
Inventory = throughput x flow time.

29. What is the difference between Lean and Six Sigma?
The gap between what management thinks customers want and the process specifications.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Lean is waste reduction - Six Sigma is variation reduction.
Inventory = throughput x flow time.

30. Define product reliability.
A tool that shows where there is waste in a process.
Mean time to failure.
The manager in charge of a process being improved in a Six Sigma project.
The Japanese national quality award.

31. The Test Statistic (TS)
100%
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Lean is waste reduction - Six Sigma is variation reduction.
A random variable that summarizes the information from the sample(s).

32. What quality guru emphasizes management as a system?
Outside.
Define - measure - analyze - design - verify.
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
Deming.

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

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34. Test for constant variance
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.
Central Limit Theorem
F_alpha - df(tr) - df (error)
Is the way in which the failure is manifested.

35. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
Look for the assignable cause of non-random variation.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
X-bar-bar

36. What do you do when a process is out of control?
50%
Variable.
Financial - customer - internal process - innovation and learning.
Look for the assignable cause of non-random variation.

37. Cause and Effect Diagrams
Lower control limit.
Method developed by Ishikawa to graphically display the causes of any given problem
10 for Hazardous without warning 1 for none
Linearity - normality - homoscedasticity - independence.

38. ANOVA

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39. In the Service Quality Gap Model - what is Gap 1?
Brand image.
The gap between what management thinks customers want and what customers really want.
10 if Almost impossible to detect
Fishbone - cause-and-effect diagram.

40. What is Kaizen?
Blame.
A brainstorming tool that shows the connections between ideas.
The gap between what management thinks customers want and the process specifications.
Rapid improvement process.

41. In the Service Quality Gap Model - what is Gap 4?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Waste.
The gap between what is promised and what is delivered.
Consumer risk.

42. What graphical tool is used to show the relationship between two numerical variables?
Attribute.
Defects Per Million Opportunities
Large enough to find two of the attribute - on average.
A scatterplot.

43. Failure Mode
Method developed by Ishikawa to graphically display the causes of any given problem
The US national quality award.
Is the way in which the failure is manifested.
Upper control limit.

44. If a three-stage process has 90% yields at each stage - what is the overall yield?
No -- if it is not the same - it can only be worse!
0.9^3 or 72.9%
A diagram that shows the relationships between activities in a project network.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

45. Define perceived quality (Garvin's framework).
Prevention and appraisal costs are balanced against internal and external failure.
A tool that shows the physical flows through a space.
A diagram that shows the relationships between activities in a project network.
Brand image.

46. PFMEA
Speed - courtesy - competence - and ease of repair.
Before production starts
Workers - machines - materials.
To mentor/coach (and sometimes train) black belts.

47. In a Z table - what is Z?
Lower skill requirements - faster - less chance for error.
Mistake-proofing.
A random variable that summarizes the information from the sample(s).
The number of standard deviations some value is from the mean.

48. What is the formula for standard deviation?
No -- the variation also has to be random and "expected."
Causes that lead to a particular effect.
99.73%
=sqrt(Σ(x-x-bar)^2)/(n-1))

49. What are the Five Dimensions of Service Quality?
Large enough to find two of the attribute - on average.
Attribute
Reliability - Assurance - Responsiveness - Tangibles - Empathy
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

50. What are the three main categories of assignable cause?
Concluding there has not been an effect/change when there has.
To obtain a certain desirable outcome from the process
F_alpha - df(tr) - df (error)
Workers - machines - materials.

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Six Sigma

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