ISE 398

While philosophies vary the common threads regarding Six Sigma include:

-A management environment that supports these initiatives as a business strategy. -Use of teams that are assigned well-defined projects that have direct impact on the organization's bottom line and continual effort to reduce variation. -A continual effort to reduce variation in all processes within the organization. -Use of teams that are assigned well-defined projects that have direct impact on the organization's bottom line.

In order to eliminate or minimize error in data collection it is recommended to:

-Be careful of rounding off measurements and losing precision. Eliminate emotional bias to the extent possible. -Carefully train those collecting data.

Common Gage R&R errors include:

All responses are common errors.

A simple 2-factor experiment with factors A and B yields the result below. This is indicative of:

An interaction between Factor A and Factor B.

SIPOC Analysis:

Associates together the suppliers and customers with the main process(es) under study and visually defines a process by identifying key activities, outputs and inputs of each process.

Non-value added activity:

Both does not change the form/function and the customer is unwilling to pay for it.

A Central Composite Design is good for building quadratic models for Response Surface Methodology. The benefit is generally

Both faster convergence and fewer experiments.

Correlation:

Both finds a relationship and measures strength/direction.

Which graphical method provides a pictorial view of minimum, maximum, median, and quartile range in one graph?

Box-and-Whisker plots.

Consider the fabrication of shirts where you track the defects as shown below using a Pareto Chart. Using the 80-20 Pareto analysis, which defects should you concentrate on eliminating/minimizing?

Button, pocket, collar (these are the 3 items that cause 80% of the problems which is indicated on right side of graph)

Root cause analysis:

Can use a Fishbone diagram, 5 Why's or FMEA for analysis applied to preventative action to stop a problem from becoming acute.

Your company is in a very competitive space and is currently supplies information to a professional society survey sent to other companies, some competitors. The survey results are shared but without company names and you use this to assess issues impacting the industry. This is known as what type of benchmarking?

Collaborative benchmarking

In experimental design, it is important to do the following for the experiment to be valid and successful:

Confirm measurement system capability and measure a stable process.

In experimental design, if there are a large number of variables and we do not know which are significant nor have the time/resources to explore all combinations, then:

Consider a fractional factorial design although we may not be able to estimate all parameters.

Which of the following steps does add value?

Creating a better surface finish that is nonfunctional but highly desired by customers due to aestetics. Injection molding a Lego piece to desired shape.

In the storming stage which of the following is not true:

Despite conflict, much is accomplished.

There are several phases of taking corrective action. After identification of the opportunity and analysis of the current state it is important to:

Develop the optimal solution and implement the changes. -Standardize the solution to prevent backsliding. -Study the results and verify the problem has been solved

A clinic performs outpatient eye surgery. For cataract surgery (e.g. Remove the lens and replace with a synthetic one) your clinic wants the patient to last no more than 2.5 hours. Specify the null and alternate hypotheses to test this with data from the last 100 surgeries.

H0: Patient time in clinic is less than or equal to 2.5 hours H1: Patient time is system is greater than 2.5 hours.

Modern cost of quality curves (compared to traditional cost of quality curves):

Has a lower cost of conformance.

Single Minute Exchange of Dies (SMED) seeks to minimize set-up time. Consider that changing of a die (labeled "first die) and placing a new die (labeled "second die") in the press. Which of the following actions would reduce the set-up time?

Have both dies have the same height (e.g. same shut height) and have two wheeled carts (one for the first die to exit and one for the second die to arrive).

You are investigating the manufacture of automotive drive shafts at four different times (in order- t1 to t4) with the distribution of shaft diameters shown below. This pattern is indicative of:

Increasing chance of non-conforming parts. (graphs get larger from t1 skinniest to t4 more spread out)

You work in a distribution center for Amazon and the main conveyor belt that distributes boxes to trucks is failing, so you perform a 5 Why's analysis as shown below. The root cause of the failure is:

Instructions about the maximum load/weight are being ignored.

Randomization in experimental design trials:

Is a method of organizing the experiment to lessen the effects of special cause variation by randomly assigning them throughout the experiment.

In lean manufacturing an Andon:

Is a visual system to notify management and maintenance of a quality or process problem.

Internal set-up:

Is done in a way that interrupts production

Which of the following steps does not add value?

Machining a feature that does not contribute to functionality but required little time.

Kanban is a pull system for production that features:

Making only what a customer orders and using bins that when empty signal that more parts are needed.

Extrapolation of regression curves:

May result in predictions that can be quite inaccurate.

In the forming stage:

Members develop a sense of belonging to the group and may tend to agree too much on in initial discussion topics.

Reducing the set-up time does which of the following?

Minimizes waste, Reduces the time required to manufacture a specific number of parts., Reduces the cost of each part., Reduces cost and improves quality.

Poka-Yoke:

Mistake-proofs a process.

A warehouse has discovered they have too many lost time accidents due to back strain. They set up an experiment to look at box weight, box size and posture while lifting, while measuring respiration and muscle response. The temperature and humidity in the warehouse (in a statistical sense) are considered:

Noise factors.

Regarding Force-Field Analysis and Nominal Group Technique, which of the following is not true:

Nominal group technique encourages debate during the brainstorming process.

Which statement below fully describes the Interrelational Digraph pictured below as it pertains to healthcare?

Nurse Availability is the driver and Scheduled Appointmentsis the critical outcome. (nurse availability arrows are out , schedule appts. arrows into it)

What type of data allows for "greater than" and "less than" operations, and specification of median and interquartile range?

Ordinal

This type of virtual team is formed from members of one role coming together to perform regular and ongoing work. They have clearly defined roles, work independently and their output is combined to produce a final result.

Production teams

Examples of process controls include:

Raw material acceptance or failure Ongoing monitoring First piece inspection

The core principle of Lean is to:

Reduce waste. Reduce non-value added activities.

In the Norming State the leader:

Reduces the level of directive behavior and increases supportive behavior, and assists the team to move to a performing stage before it reverts to earlier stages

A process Kaizen:

Removes waste (muda) from a specific process or subprocess

In Gage R&R studies, ____________ is variation due to the gage and ____________ is due to operators.

Repeatability, reproducibility

It is important to understand the difference between accuracy and precision when dealing with measurement data. From the figure below identify which is accurate but not precise.

Result 3 , spread out but all around the center

Reducing inventory:

Reveals issues with equipment downtime. Reveals problems due to long set-up time. Reveals deficiencies in production planning and control. Reveals deficiencies in production.

Factors that contribute to lower Overall Equipment Effectiveness (OEE) include:

Running at a different speed to accommodate input material differences Scrap Machine faults

Response Surface Methodology:

Seeks to optimize a physical process or service by determining the gradient around a center point and moving the center of a new experiment to seek optimality.

Ishikawa (Fishbone) diagrams

Should consider Man (people), Machine, Methods, Materials, Measure and Mother Nature.

Control plans:

Should contain a release number and date to ensure the most up to date plan is used. Specify actions for troubleshooting, correction and restoration. Details who makes decisions and carries out actions.

Project proposals are used to decide which Six Sigma projects are to be tackled at a particular time. The proposals:

Should contain both precise statements of project definition and some preliminary measures of seriousness. Should also be in step with organizational goals.

Value stream mapping considers:

Strives for customer pull and flow of materials and information from receipt of supplier material to delivery of finished goods and services to customers.

Flowcharts and other graphical means allow for ISE's to better understand flow. Consider a warehouse that deals with many "hand-offs" between the customer, customer support and warehouse operations. Which graphical method below allows for the best (easiest) understanding of the roles of each and the hand-offs that occur?

Swim lane diagrams (or swim flowchart)

A company received parts from two vendors and the statistical difference in defects level is 0.4% with equivalent variance. Customer survey results indicate that a 1.9% difference in defects would still meet customer expectations. The 1.9% difference is:

The practical significance.

The statistical power of a hypothesis test is:

The probability of detecting an effect, if there is a true effect present to detect.

All design issues are not equally important. The level of risk is typically determined by:

The probability of occurrence and severity of the consequences.

In the Theory of Constraints:

The rates of all processes are adjusted to match the output rate of the constraining process.

When designing a regression experiment is important to:

Understand all variables that should be included.

Which of the following is a type of waste (or muda)?

Waiting and correction of mistakes., Waiting.,Necessary human motion.,Correction of mistakes.

When collecting data, average measurements of an absolute value may drift over time. This source of variation is known as what type of error?

calibration

Sometimes there is little homogeneity in a lot since there is a mixture of parts from different streams (such as different raw material lots). This requires what type of sampling for inspection?

stratified

With complex systems including military product small samples often result in:

test designs that require the system to perform at levels well above the specified level to ensure that the power of the test approaches reasonable values.

A Type II error occurs when:

the researcher fails to reject a null hypothesis when it is false.

Consider Multi-Vari study of the dimensions of an additive manufactured metal component. Your interest is in the external dimention. Such a study looks for sources of variation that include:

within a part temporal part-to-part