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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. What are the four categories of costs in Juran's framework?
Taguchi
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Prevention - appraisal - internal failure - external failure.
10 if Almost impossible to detect

2. Pareto Analysis
Mistake-proofing.
0.9^3 or 72.9%
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
=sqrt(Σ(x-x-bar)^2)/(n-1))

3. 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
Causes that lead to a particular effect.
An assertion or conjecture concerning one or more populations
68%

4. Uses of regression - Control
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Pleasing to the senses.
To obtain a certain desirable outcome from the process
Prevention - appraisal - internal failure - external failure.

5. What is the Deming Prize?
A brainstorming tool that shows the connections between ideas.
The Japanese national quality award.
50%
The US national quality award.

6. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Variable.
X-bar-bar
99.73%
The manager in charge of a process being improved in a Six Sigma project.

7. Detection Criteria Ranking
The House of Quality.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Studying firms with the best performance in a particular area.
10 if Almost impossible to detect

8. There are two milling machines in the shop. Data has been collected on one to compute control limits for both. This is acceptable SPC practice - true or false and why?
False - because each machine will have different natural tolerances.
Before production starts
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

9. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
Workers - machines - materials.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Sort - Set in Order - Shine - Standardize - Sustain

10. TWO-DIMENTIONAL SCATTER PLOT
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Observed variation in response is caused by the input
A diagram that shows the relationships between activities in a project network.

11. Defect check sheets
Different types of defects are listed (used for Pareto chart)
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.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Method developed by Ishikawa to graphically display the causes of any given problem

12. What is the role of a master black belt?
Sort - Set in Order - Shine - Standardize - Sustain
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:
To mentor/coach (and sometimes train) black belts.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

13. What is the center line of an X-bar chart?
Look for the assignable cause of non-random variation.
X-bar-bar
The gap between what management thinks customers want and what customers really want.
Lower control limit.

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

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15. Affinity Diagrams
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
99.73%
A tool that shows where there is waste in a process.
Waste.

16. What happens to control limits on an SPC chart when sample size is increased?
Failure Modes and Effects Analysis
They move closer to the center line.
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

17. 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.
Conformance to specifications.
Can't tell without a Range chart.
The degree to which a product meets pre-established standards.

18. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Someone who is consistently against virtually everything.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Scrap - rework - retest - downtime - yield losses - disposition costs.
Attribute

19. One factor at a time (OFAT)
Observed variation in response is caused by the input
Variable.
Lean is waste reduction - Six Sigma is variation reduction.
To mentor/coach (and sometimes train) black belts.

20. When is Cpk used?
Is the way in which the failure is manifested.
Observed variation in response is caused by the input
To do a capability study for a non-centered process.
A diagram that shows the relationships between activities in a project network.

21. 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.
Prevention - appraisal - internal failure - external failure.
Lower control limit.
Variable.

22. What is a network diagram?
Hold all input variables constant except one. Observe the response as you vary the single input.
A random variable that summarizes the information from the sample(s).
Actual drawings - layouts - maps - etc which show where a defect occurs
A diagram that shows the relationships between activities in a project network.

23. If a three-stage process has 90% yields at each stage - what is the overall yield?
= 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 descending order-sorted bar chart with a cumulative percentage line.
0.9^3 or 72.9%
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

24. In the Service Quality Gap Model - what is Gap 4?
The gap between what is promised and what is delivered.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Is the consequence of the failure.

25. What quality tool formally incorporates the voice of the customer?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Outside.
Financial - customer - internal process - innovation and learning.
QFD

26. The Test Statistic (TS)
A random variable that summarizes the information from the sample(s).
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.
Walter A. Shewhart
Fractional factorial designs (orthogonal arrays)

27. Define aesthetic quality.
Pleasing to the senses.
Fractional factorial designs (orthogonal arrays)
Someone who is consistently against virtually everything.
A scatterplot.

28. Which type of SPC measurement is more precise - variable or attribute?
Brand image.
Variable.
An assertion or conjecture concerning one or more populations
Actual drawings - layouts - maps - etc which show where a defect occurs

29. F value
F_alpha - df(tr) - df (error)
The ratio of outputs to inputs; 1-scrap.
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).
Fewer good units to sell - increased variable cost/unit.

30. Process occurance ranking
To manage the Six Sigma project.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Workers - machines - materials.
Different types of defects are listed (used for Pareto chart)

31. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Fishbone - cause-and-effect diagram.
68%
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Method developed by Ishikawa to graphically display the causes of any given problem

32. When yields decrease - what are the two effects on contribution?
Fewer good units to sell - increased variable cost/unit.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
A time series plot.
Is the consequence of the failure.

33. What is a spaghetti diagram?
The Japanese national quality award.
A tool that shows the physical flows through a space.
=sqrt((p*(1-p)/n)
Assigns scores to weighted criteria for each project under consideration.

34. Regression
Blame.
68%
Represents the behavior of a process
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

35. What percentage of a normal distribution lies above the mean?
p-bar - the long-run percent defective.
50%
Organize ideas into meaningful categories by recognizing their underlying similarity
Assigns scores to weighted criteria for each project under consideration.

36. Advantages of DOE
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
It's good -- but it's still out of control!
No -- the variation also has to be random and "expected."
99.73%

37. PFMEA
Fewer good units to sell - increased variable cost/unit.
Lean (or JIT).
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Before production starts

38. Define benchmarking.
Someone who is consistently against virtually everything.
Speed - courtesy - competence - and ease of repair.
A tool that shows where there is waste in a process.
Studying firms with the best performance in a particular area.

39. What is muda
What the value of the dependent variable is when the independent variable is zero.
Someone who is consistently against virtually everything.
A diagram that shows the relationships between activities in a project network.
Waste.

40. Failure effect
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Is what induces the failure
Is the consequence of the failure.
Defects Per Million Opportunities

41. What is the formula for standard deviation?
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
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
What the value of the dependent variable is when the independent variable is zero.
=sqrt(Σ(x-x-bar)^2)/(n-1))

42. What are the 5 Ss?
Sort - Set in Order - Shine - Standardize - Sustain
Inventory = throughput x flow time.
Different types of defects are listed (used for Pareto chart)
10 for Hazardous without warning 1 for none

43. What do you do when a process is out of control?
Look for the assignable cause of non-random variation.
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:
Is the way in which the failure is manifested.
Variable.

44. For what is an x-bar chart used?
F_alpha - df(tr) - df (error)
To monitor a process when measurement by variables is used.
100%
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

45. In a regression - what does the p value of F tell you?
Attribute
Concluding there has been an effect/change when there has not.
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).
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

46. In the Service Quality Gap Model - what is Gap 5?
No -- if it is not the same - it can only be worse!
Fishbone - cause-and-effect diagram.
The gap between what customers expect and the service they receive.
A descending order-sorted bar chart with a cumulative percentage line.

47. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The cycle time required to meet demand.
Attribute

48. What is an affinity diagram?
A brainstorming tool that shows the connections between ideas.
Variable.
No -- only if the process is also capable.
No -- the variation also has to be random and "expected."

49. Effect ranking (Severity of the Defect)
10 for Hazardous without warning 1 for none
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Critical to quality.
Central Limit Theorem

50. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
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.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
99.73%
Prevention and appraisal costs are balanced against internal and external failure.

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