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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. What does Crosby say about benchmarking?
Lean (or JIT).
Controlling quality at the source.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

2. Process occurance ranking
To manage the Six Sigma project.
Fitness for use.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Scrap - rework - retest - downtime - yield losses - disposition costs.

3. What is Value Stream Mapping?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Attribute
A tool that shows where there is waste in a process.

4. Definition of Interaction
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Lean is waste reduction - Six Sigma is variation reduction.
An assertion or conjecture concerning one or more populations

5. Daniel Test
Controlling quality at the source.
50%
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
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:

6. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
The gap between what management thinks customers want and what customers really want.

7. What type of risk is associated with Type II Error?
False - because each machine will have different natural tolerances.
Consumer risk.
The ability of a process to consistently meet customer specifications.
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.

8. Residual(eij)
= yij - y(bar)i --> value minus sum of that treatment (of row)
To monitor a process when measurement by variables is used.
10 for Hazardous without warning 1 for none
Look for the assignable cause of non-random variation.

9. What are the three main categories of assignable cause?
95%
Mistake-proofing.
Workers - machines - materials.
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

10. Based on what principal can we use the normal distribution assumptions for SPC?
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
Central Limit Theorem
Financial - customer - internal process - innovation and learning.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

11. List two components of prevention cost.
An assertion or conjecture concerning one or more populations
Attribute
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Fractional factorial designs (orthogonal arrays)

12. What is the 5S model?
The target number of standard deviations from the mean for specifications.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Pleasing to the senses.
Studying firms with the best performance in a particular area.

13. What is muda
Waste.
A time series plot.
Producer risk.
50%

14. Who is a process owner?
The gap between what is promised and what is delivered.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
The manager in charge of a process being improved in a Six Sigma project.
Waste.

15. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Conformance to specifications.
Walter A. Shewhart
The cycle time required to meet demand.
Represents the behavior of a process

16. Defect check sheets
No -- the variation also has to be random and "expected."
Inventory = throughput x flow time.
Prevention and appraisal costs are balanced against internal and external failure.
Different types of defects are listed (used for Pareto chart)

17. Affinity Diagrams
The gap between what management thinks customers want and what customers really want.
Consumer risk.
Organize ideas into meaningful categories by recognizing their underlying similarity
Sort - Set in Order - Shine - Standardize - Sustain

18. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Variable.
Sampling for SPC is done real time.
Fractional factorial designs (orthogonal arrays)
Is what induces the failure

19. Simple Regression Analysis (one factor regression model)
The gap between what management thinks customers want and the process specifications.
Supplier - input - process - output - customer.
Fitness for use.
= 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

20. What is the center line of a p-chart?
99.73%
= 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
68%
p-bar - the long-run percent defective.

21. What graphical tool is used to show the relationship between two numerical variables?
Mean time to failure.
A scatterplot.
To manage the Six Sigma project.
Lean (or JIT).

22. What are the four perspectives of the Balanced Scorecard?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Is the consequence of the failure.
Financial - customer - internal process - innovation and learning.
Controlling quality at the source.

23. What are the 5 Ss?
Producer risk.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Financial - customer - internal process - innovation and learning.
Sort - Set in Order - Shine - Standardize - Sustain

24. In a regression - what does the p value of F tell you?
F_alpha - df(tr) - df (error)
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
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 US national quality award.

25. Who developed the fishbone diagram?
Mean time to failure.
Kaoru Ishikawa.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

26. One factor at a time (OFAT)
A time series plot.
Hold all input variables constant except one. Observe the response as you vary the single input.
X-bar-bar
An assertion or conjecture concerning one or more populations

27. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Define - measure - analyze - improve - control.
Prevention and appraisal costs are balanced against internal and external failure.
Central Limit Theorem
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

28. If you have calculated a Cpk - should you also calculate a Cp?
68%
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Not necessarily.

29. Define serviceability.
Failure Modes and Effects Analysis
Speed - courtesy - competence - and ease of repair.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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.

30. List two components of internal failure.
Prevention - appraisal - internal failure - external failure.
The secondary characteristics of a product; "bells and whistles."
The gap between specifications and how service is performed.
Scrap - rework - retest - downtime - yield losses - disposition costs.

31. PFMEA
Inventory = throughput x flow time.
Lower skill requirements - faster - less chance for error.
Before production starts
Controlling quality at the source.

32. DOE
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

33. Which quality guru developed the concept of loss to society?
10 for Hazardous without warning 1 for none
Taguchi
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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. F value
F_alpha - df(tr) - df (error)
Lower skill requirements - faster - less chance for error.
The House of Quality.
Controlling quality at the source.

35. In the Service Quality Gap Model - what is Gap 3?
The gap between specifications and how service is performed.
Variable.
Conformance to specifications.
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).

36. TWO-DIMENTIONAL SCATTER PLOT
The gap between what management thinks customers want and the process specifications.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
=sqrt((p*(1-p)/n)
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

37. 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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38. Define features.
The secondary characteristics of a product; "bells and whistles."
Lower control limit.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Defects Per Million Opportunities

39. To what does the Six in Six Sigma relate?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
10 for Hazardous without warning 1 for none
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The target number of standard deviations from the mean for specifications.

40. Which type of SPC measurement is more precise - variable or attribute?
Variable.
Not necessarily.
Concluding there has been an effect/change when there has not.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

41. What are the Five Dimensions of Service Quality?
Through producer/consumer negotiation.
It's good -- but it's still out of control!
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

42. What type of risk is associated with Type 1 Error?
Producer risk.
Failure Modes and Effects Analysis
Sort - Set in Order - Shine - Standardize - Sustain
Kaoru Ishikawa.

43. What is a run chart?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Fewer good units to sell - increased variable cost/unit.
A time series plot.
The target number of standard deviations from the mean for specifications.

44. Define performance quality.
Defects Per Million Opportunities
Large enough to find two of the attribute - on average.
The primary operating characteristics of a product.
Workers - machines - materials.

45. What are the four categories of costs in Juran's framework?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Represents the behavior of a process
Prevention - appraisal - internal failure - external 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).

46. Statistical Hypothesis
= 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
F_alpha - df(tr) - df (error)
100%
An assertion or conjecture concerning one or more populations

47. What is Type 1 Error?
Waste.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Concluding there has been an effect/change when there has not.

48. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Mistake-proofing.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

49. List two components of external failure.
Is what induces the failure
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
=sqrt(Σ(x-x-bar)^2)/(n-1))

50. What is DMADV?
Workers - machines - materials.
Define - measure - analyze - design - verify.
Linearity - normality - homoscedasticity - independence.
Observed variation in response is caused by the input

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