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Question

What is Pareto Principle?

Answer 1

The Pareto principle (or the 80/20 Rule) states that, for many events, roughly 80% of the effects come from 20% of the causes

Answer 2

The different kinds of variation are — mean, median, range and mode.

Answer 3

1. Executive leaders 2. Champions 3. Master black belt 4. Black belts 5. Green belts Executive leaders: The decision of to six sigma is taken by the main team – Executive Leaders. They promote the six sigma throughout the enterprise and ensure the commitment of the enterprise in six sigma. The executive leaders are mainly CEO, or some of the board of directors. The six sigma initiative is funded by Executive leaders. The executive leaders should be confident and determine that six sigma will improve organization process and it is succeeded. Champions: Champions are normally the senior manager of the enterprise. He promotes six sigma mainly among the users of the business. He acts as a coach, mentor, selects projects, decides the objectives, allocates the resources and removes hurdles from black belt players. The champions fight for removing black belt hurdles. Master Black-Belt: This role highly demands the technical capability in six sigma. All organizations are not started with six sigma and will not have the same. Normally outsiders are recruited for it. The key role of Master Black-belt is train, mentor and guide. He supports the executive leaders in candidate’s selection; teach the fundamentals and train resources and right project for resources. Black-Belt: Black-belt always leads a selected project team for show casing six sigma. Their responsibilities include finding out the variations and looking after minimizing the variations. Black belt normally selects the projects, train resources, and they are the real implementers of the project. They are the core resources to six sigma as the actual implementation of six sigma is done by black belt, in the enterprise. Green Belt: The green belt resources supports black belt in the functionality areas. They are part time resources who work mainly on projects for six sigma implementation. The six sigma methodologies for solving problems are applied by green belt and help for defining the basic six sigma implementation of the enterprise. The too support black belt in implementing six sigma in the enterprise.

Answer 4

This cause analysis tool is considered one of the seven basic quality tools. The fishbone diagram identifies many possible causes for an effect or problem. It can be used to structure a brainstorming session. It immediately sorts ideas into useful categories. ``` Methods Machines (equipment) People (manpower) Materials Measurement Environment ```

Answer 5

Cause-and-effect diagram (also called Ishikawa or fishbone diagrams): Identifies many possible causes for an effect or problem and sorts ideas into useful categories. Check sheet: A structured, prepared form for collecting and analyzing data; a generic tool that can be adapted for a wide variety of purposes. Control chart: Graph used to study how a process changes over time. Comparing current data to historical control limits leads to conclusions about whether the process variation is consistent (in control) or is unpredictable (out of control, affected by special causes of variation). Histogram: The most commonly used graph for showing frequency distributions, or how often each different value in a set of data occurs. Pareto chart: A bar graph that shows which factors are more significant. Scatter diagram: Graphs pairs of numerical data, one variable on each axis, to look for a relationship. Stratification: The process of dividing a process into subgroups (strata) based on inherent characteristics such as: age group, ethnicity, occupation etc in order to obtain a representative sample for analysis (some lists replace stratification with flowchart or run chart).

Answer 6

It is the process of putting demand on a software system or computing device and measuring its process

Answer 7

Cpk is process capability index, which measures how close a process is running to its specification limits, relative to the natural variability of the process and Ppk is process performance index, which verifies if the sample that have been generated from the process is capable of meeting Customer CTQs (requirements).

Answer 8

Cp and Cpk measure how consistent you are to around your average performance. The ‘k’ stands for ‘centralizing factor.’ The index takes into consideration the fact that your data is maybe not centered. Cpk tells us what a process is capable of doing in future, assuming it remains in a state of statistical control. Cp assumes the process is centered (i.e. what the ideal can be).

Answer 9

measure of the amount of variation or dispersion of a set of values. A low standard deviation indicates that the values tend to be close to the mean (also called the expected value) of the set, while a high standard deviation indicates that the values are spread out over a wider range.

Answer 10

The 1.5 sigma shift adjustment takes into account what happens to every process over many cycles of manufacturing.

Answer 11

Regression Analysis is a technique used to define relationship between an output variable and a set of input variables. There are several types of regression like Simple Linear Regression, Multiple Linear Regression, Curvilinear Regression, Logit Regression and Probit Regression etc., which caters to a variety of requirements based on the type of underlying data.

Answer 12

A defect is any non-conformance of the unit of product with the specified requirements. A defective is a unit of product which contains one or more defects.

Answer 13

Process Report is used with continuous data that follow a bell curve distribution, while Product Report applies to discrete data and therefore can be used for all type of distributions.

Answer 14

Failure Mode Effects Analysis (FMEA) is a tool to quantify and prioritize risk within a Six Sigma process, product, or system. Uses Severity, Occurrence, Detection to get RPM. FMEA is a qualitative and systematic tool, usually created within a spreadsheet, to help practitioners anticipate what might go wrong with a product or process.

Answer 15

They are a set of two charts, which is the most commonly used statistical process control procedure used to monitor process behavior and outcome over time.

Answer 16

A flowchart is a diagram displaying the sequential steps of an event, process, or workflow. Brainstorming is a technique used to quickly generate creative or original ideas on or about a process, problem, product, or service.

Answer 17

SIPOC is acronym for Supplies, Inputs, Process, Outputs and Customers. It is a tool that uses information from these five segment and creates a process map, providing a high-level overview of a Six Sigma project. Many organizations these days use the opposite acronym COPIS, putting customers first and explaining the value of a customer to the organization.

Answer 18

DFSS is the acronym for Define for Six Sigma. It is a process improvement system that involves designing or redesigning a service or a product as per Six Sigma quality standards.

Answer 19

ARMI is an abbreviation for Approver, Resource, Member and Interested Party. It is a project management tool to identify the personnel involved in a project and their key responsibility areas.

Answer 20

A data collection plan is used to collect all the important data in a system. It covers – Type of data that needs to be collected or gathered Different data sources for analyzing a data set

Answer 21

The full form of MSA is Measurement System Analysis. MSA is used to check if a measurement system is accurate. It evaluates a system’s accuracy, precision and stability.

Answer 22

It is a process in Six Sigma implementation, which is in line with the business strategy and consumer requirements, and paves way for common understanding and nomenclature. On the other hand, the major disadvantage of this process is that it has a very broad scope, thus is difficult to be executed within a stipulated time.

Answer 23

It is the acronym of Value Stream Mapping. This methodology is used to eliminate wastes from a process and map the flow of information required to deliver a product or service.

Answer 24

An Affinity Diagram is an analytical tool used to cluster or organize ideas into subgroups. These ideas are mostly generating from discussions or brainstorming sessions and used in analyzing complex issues.

Answer 25

A histogram graphical represents the frequency distribution of numeric data, while a Boxplot summarizes the important aspects of continuous data distribution including outliers.

Answer 26

Well, the cost of six sigma implementation is estimated by the organization in different ways and few of the popular ones are listed below: 1. The cost associated with six sigma implementation can be paid out from the direct payroll of the company and identify the individuals who were involved in this process full time and paid accordingly 2. This is an indirect payroll policy where the individuals are identified and payout based on the activities like data gathering, measurements, and discussions with the product owners etc. 3. This is purely a consultative approach, where the consultants will be paid based on the number of hours they have to spend to train and mentor the team 4. This is completely a different approach towards six sigma process. The payout can happen based on the process improvisation.

Answer 27

It is a method, where a set of tools is used to measure process quality. It signifies how well the business process is monitored. Each sigma level corresponds to a number of acceptable defects per million. The optimum sigma level is attained when business process accuracy goes to 3.4 defects per million opportunities. The list below highlights the admissible no of defects per million in correspondence to each sigma level: 1 – 690,000 2 – 3,08,537 3 – 66, 807 4 – 6, 210 5 – 233 6 – 3.4

Answer 28

Load testing tests a program or an application on its capacity to handle a certain limit, where the load limit is beyond the client’s requirement. Performance testing is used to test the responsiveness and stability of a particular program or system under a certain workload. Thus, it is inclusive of load testing and stress testing.

Answer 29

Graphical method to caption present the complex critical thought processes used to solve the problem or achieve a defined goal. It is a method to organise the project and document the wise behind all of the actions. The process is summarised by three steps: 1) Ask - The right question at the right time 2) Act - Using the right tool at the right time 3) Answer - Using the right tool correctly to answer the right question

Answer 30

Surveys are a method of drawing broad conclusions about populations by collecting a sample of information from a smaller group of individuals. They can include phone interviews, emails surveys, and in-person interviews

Answer 31

The 3 key elements for the six sigma process improvement are customer, process, and employees.

Answer 32

The Open step: In this step, all the team members gather together and do a brainstorming session on all possible scenarios. The Narrow step: They narrow down all the possible explanations and scenarios are to an extent considering the current performance. The close step: The project team validates all the narrowed down explanations for the current performance.

Answer 33

Communicates strategic plan of an organisation by showing the cause and effect relationship of strategic objectives (called a strategy map) across four perspectives: people processes customer financial Achievement on a particular objective is based on one to two measures and related targets and project initiatives are established to drive an achievement of an objective. The matrix of objectives, measures, targets and initiatives is called a score card. Together, the strategy map and the scorecard form the balanced scorecard.

Answer 34

``` Use a project prioritisation calculator and multiply the ratings against several factors such as: importance to customer cost to implement likelihood of success cost reduction positive impact on other processes ```

Answer 35

The purpose of a project charter is to define the focus, scope, direction, and motivation for a team. The project champion typically creates the preliminary charter with the team leader. The project team reviews the draft and provides input for the champion’s final approval. Key components of a project charter include: Business case – financial impact, why important, why now Problem statement Project scope – what are the boundaries, or what is in scope and what is out of scope Goal statement or success measures Roles of team members Milestones and deliverables – what needs to be accomplished and delivered by when The project charter can be, and often is, modified through the analyze phase of an improvement project. After the analyze phase is complete, no further changes should occur.

Answer 36

The longest series of linked tasks that must be completed before the last task. Any delay in the critical path will impact the timing of the final task.

Answer 37

Forming Storming Norming Performing Forming: members learn how to deal with one another Storming: swirling change, individual emotion and group conflict; the team formally clarifies its goals, determines individual roles, identifies barriers, forges relationships and determines the necessary infrastructure support mechanism, Norming: teams continue to resolve issues generated in the storming phase and reach consensus on the team's future state becoming more productive Performing: as teams mature they enter the most productive phase of team development -

Answer 38

``` Shock Denial Frustration Depression Experiment Decision Integration ```

Answer 39

``` Identify - segment and target Gather - active and passive information Sort - affinity diagram Develop - CTQC tree Translate - develop specifications ```

Answer 40

It defines the group of individuals that will be sampled. If the frame excludes certain groups of individuals, sample error will be introduced. For greatest accuracy, the survey frame should be drawn to provide a fully representative sample.

Answer 41

Term commonly used to convey the degree of uncertainty about the results of a sample survey in order to draw conclusions about the populations from which it was taken. The two types of errors are non-sampling error, which arises when people don't understand questions, decline to participate or do not tell the truth. Sampling error is a function of sample size, variability of the population and to a lesser extent the size of the population. For a given population variability, the greater the sample size the lower the sampling error (subject to diminishing return).

Answer 42

A clear, unambiguous, observable and measurable standard of acceptance for each Critical to Quality Characteristic.

Answer 43

Quality Function Deployment. Structured approach to defining customer needs or requirements and translating them into specific plans to produce products to meet those needs. The matrices are used to translate higher level "whats" or needs into lower levels "hows" - product requirements or technical characteristics to satisfy these needs.

Answer 44

Japanese term meaning to go observe what is happening in the actual place where value is created, engage the people who do the work, and ask questions to understand. "Go see, ask why, show respect"

Answer 45

SIPOC - identifies suppliers, inputs, outputs and customers Flow Chart - show decision points and if/then logic Deployment Flow Chart (Swimlane Chart) - identifies functional responsibilities Value added flow chart - separates value added from non value added operations (identifies waste) Spaghetti diagram - shows physical flow of material and/or information, thus illustrating physical complexity, distance travelled and cycle time Value stream map - identifies physical flow of materials and information, quantifies inventory levels, process characteristics and control mechanisms System diagram - focussed on systemic cause and effects, shows reinforcing and balancing forces along with unintended consequences

Answer 46

Refers specifically to the pace of customer demand - is the time required to produce one unit if production is matched to customer demand. It is calculated by dividing the total available process time by the total quantity required by the customer

Answer 47

Population: entire process output or collection of objects about which we wish to draw a conclusion Sample: a subset chosen to represent the population Random sample: sample drawn such that every member of the population has an equal chance of being select Parameter: quantity associated with the population, designated by greek and capital roman letters. E.g. P (proportion), mu (average), sigma (std. dev.) Statistic: quantity calculated from the sample, designated by lower case roman letters. E.g. p (proportion), y-bar (average), s (std. dev.)

Answer 48

Descriptive statistic aim to describe and summarise the important features of a population or process e.g. graphical - pie, bar, line, histogram, scatter numerical - proportion, mean, median, mode, range, variance, standard deviation, correlation, skewness Inferential statistics uses sampled data to make comparisons among, or draw inferences about the effects of different solutions or treatments on the overall population e.g. regression analysis (simple/multiple), hypothesis testing, confidence interval, design of experiments, data modelling and response surface analysis. Control charts are examples of both as they observe the process over time to establish stability (describe) and signal the effect of special cause as soon as the process displays instability (inference)

Answer 49

Discrete representation of categories or attributes Continuous is derived from the scale of continuum, that is infinitely divisible Discrete types: Nominal: groups are labels and have no order, e.g. colours of a car, pass or fail Ordinal: groups are a logical order, e.g. small/med/large and education level Counts: number of items or events

Answer 50

A single value that attempts to describe a set of data by identifying the central position within that set of data e.g. mean, median, mode

Answer 51

To understand how dispersed the process is we use range, variance and std. deviation

Answer 52

As the sample size increases the distribution of the sample mean tends towards the normal, irrespective of the shape of the original (parent) population

Answer 53

+-1 - 68% +-2 - 95% +-3 - 99.7%

Answer 54

1) Create a histogram and overlay a normal distribution curve 2) Use a normal probability plot which plots cumulative % or proportion on the y-axis and observation values on the x-axis. A normal distribution is a straight diagonal line.

Answer 55

Measurement system analysis is a process to determine whether a measurement system is capable of providing information which is reliable enough to base decisions based on its output. This is done by quantifying its accuracy, precision and stability.

Answer 56

Location (Average measurement value vs actual value): Stability refers to the capacity of a measurement system to produce the same values over time when measuring the same sample. i.e. the absence of "Special Cause Variation" leaving only "Common Cause Variation" Bias (accuracy) is a measure of the distance between the average value of the measurements and the "True" or "Actual" value of the sample or part. Linearity is a measure of the consistency of bias over the range of the measurement device Variation (spread of measurement values - precision): repeatability assesses whether the same appraiser can measure the same part/sample multiple times with the same measurement device and get the same value Reproducibility asses whether different appraisers can measure the same part/sample with the same measurement device and get the same value

Answer 57

Statistical stability over time Variability small compared to process variability Variability small compared to specification limit(tolerance) Resolution or discrimination of the measurement device must be small relative to the smaller of either the specification tolerance or the process spread

Answer 58

Prepare: number of appraisers, parts, repeats, clear process/procedure and measurement device resolution Stability: select part from middle of process spread, measure master over 20 periods, plot on x-bar and r chart Bias: from x-bar and r chart subtract reference from x-bar to yield bias. High value can be due to: appraisers not following the procedure, error in measuring reference value, instability in the measurement e.g. device could be wearing or calibration could be drifting Linearity: 5 parts that represent operating range of measurement device, get reference value for parts, single operator measures parts, do linearity plot

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