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What is a limitation of the Cp value in measuring process capability?
What is a limitation of the Cp value in measuring process capability?
What is the purpose of the correction term (1 − K) in the Cpk metric?
What is the purpose of the correction term (1 − K) in the Cpk metric?
What does a Cpk value less than 1 indicate about a process?
What does a Cpk value less than 1 indicate about a process?
What is the statistical likelihood of non-defects in a Six Sigma quality process?
What is the statistical likelihood of non-defects in a Six Sigma quality process?
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What is the relationship between D (design center) and X-bar (process average) when Cpk is identical to Cp?
What is the relationship between D (design center) and X-bar (process average) when Cpk is identical to Cp?
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What is the purpose of the Measure phase in the Six Sigma methodology?
What is the purpose of the Measure phase in the Six Sigma methodology?
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According to the PPM table, what is the implication of a Cpk value of 0.50?
According to the PPM table, what is the implication of a Cpk value of 0.50?
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What is the formula to calculate Defects per Million Opportunities (DPMO)?
What is the formula to calculate Defects per Million Opportunities (DPMO)?
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What is the purpose of Process Capability Analysis in Six Sigma?
What is the purpose of Process Capability Analysis in Six Sigma?
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What is a 'Unit' in the context of Defects per Million Opportunities (DPMO)?
What is a 'Unit' in the context of Defects per Million Opportunities (DPMO)?
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What is the primary focus of process capability analysis in product design?
What is the primary focus of process capability analysis in product design?
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What is the formula for calculating process capability (Cp)?
What is the formula for calculating process capability (Cp)?
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What is the significance of the scatter diagram in the example of K Computers' medical equipment cart?
What is the significance of the scatter diagram in the example of K Computers' medical equipment cart?
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Why is it not possible to cut each tube to exactly the same length in K Computers' medical equipment cart?
Why is it not possible to cut each tube to exactly the same length in K Computers' medical equipment cart?
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What is the purpose of design tolerances for tubing parts in K Computers' medical equipment cart?
What is the purpose of design tolerances for tubing parts in K Computers' medical equipment cart?
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What is the purpose of process control charts in Six Sigma Quality?
What is the purpose of process control charts in Six Sigma Quality?
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What does a point outside the upper and lower limits on a process control chart indicate?
What does a point outside the upper and lower limits on a process control chart indicate?
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What is the typical range of values for a process that is capable and normal with sampling?
What is the typical range of values for a process that is capable and normal with sampling?
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What is the percentage of confidence interval usually used to define the process width?
What is the percentage of confidence interval usually used to define the process width?
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What is the primary purpose of process control analysis in Six Sigma Quality?
What is the primary purpose of process control analysis in Six Sigma Quality?
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What should be done to a process when it is 'out of control'?
What should be done to a process when it is 'out of control'?
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What is the percentage of sample mean values that fall within 3 sigma of the center line in a bell-shaped curve?
What is the percentage of sample mean values that fall within 3 sigma of the center line in a bell-shaped curve?
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What is the purpose of calculating the grand mean in the Xbar&R process?
What is the purpose of calculating the grand mean in the Xbar&R process?
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What is the value of the mean range in the given example of Xbar&R process?
What is the value of the mean range in the given example of Xbar&R process?
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What is the purpose of collecting data samples in the Xbar&R process?
What is the purpose of collecting data samples in the Xbar&R process?
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What is the significance of the '3' in the equations for computing control limits?
What is the significance of the '3' in the equations for computing control limits?
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What does the p-chart in the Six Sigma Quality process control analysis show?
What does the p-chart in the Six Sigma Quality process control analysis show?
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What do trends in a control chart typically indicate?
What do trends in a control chart typically indicate?
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What do runs in a control chart typically indicate?
What do runs in a control chart typically indicate?
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What does hugging in a control chart typically indicate?
What does hugging in a control chart typically indicate?
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What does periodicity in a control chart typically indicate?
What does periodicity in a control chart typically indicate?
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What is the purpose of process control charts in Six Sigma Quality?
What is the purpose of process control charts in Six Sigma Quality?
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What does a point outside the upper and lower limits on a process control chart indicate?
What does a point outside the upper and lower limits on a process control chart indicate?
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What is the typical range of values for a process that is capable and normal with sampling?
What is the typical range of values for a process that is capable and normal with sampling?
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What should be done to a process when it is 'out of control'?
What should be done to a process when it is 'out of control'?
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Hyundai increased the number of workers on the _______________ team from 100 to more than 850.
Hyundai increased the number of workers on the _______________ team from 100 to more than 850.
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Hyundai instituted mandatory seminars for all workers on the importance of _______________.
Hyundai instituted mandatory seminars for all workers on the importance of _______________.
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Hyundai made capital investments in problem areas, including $30 million invested in a _______________ center to test electronic systems.
Hyundai made capital investments in problem areas, including $30 million invested in a _______________ center to test electronic systems.
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Hyundai placed first in the J.D. Power Initial _______________ Study in 2014.
Hyundai placed first in the J.D. Power Initial _______________ Study in 2014.
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Quality is expected and must be delivered, as it offers firms a way of enhancing their _______________ and strategic position in the marketplace.
Quality is expected and must be delivered, as it offers firms a way of enhancing their _______________ and strategic position in the marketplace.
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Six Sigma Quality aims near ______ perfection
Six Sigma Quality aims near ______ perfection
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The ______ per Million Opportunities (DPMO) metric is used to describe the variability of the process.
The ______ per Million Opportunities (DPMO) metric is used to describe the variability of the process.
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The design specification for a tube length is _____ mm ± 10mm.
The design specification for a tube length is _____ mm ± 10mm.
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The Six Sigma Methodology consists of ______ phases: Define, Measure, Analyze, Improve, and Control.
The Six Sigma Methodology consists of ______ phases: Define, Measure, Analyze, Improve, and Control.
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The Cp is essentially the ratio of the _____ width to the process width.
The Cp is essentially the ratio of the _____ width to the process width.
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Process capability analysis is a tool for assessing the ability of a process to consistently meet or exceed a product's ______ specifications.
Process capability analysis is a tool for assessing the ability of a process to consistently meet or exceed a product's ______ specifications.
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In the Six Sigma Methodology, the ______ phase determines how to measure the process and how it is performing.
In the Six Sigma Methodology, the ______ phase determines how to measure the process and how it is performing.
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Managers in the past have chosen to set P = _____σ to define a range that covers about 99.7 percent of the output for processes that vary.
Managers in the past have chosen to set P = _____σ to define a range that covers about 99.7 percent of the output for processes that vary.
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A Cp value less than 1 would indicate that more than _____ percent of produced units will not meet design specifications.
A Cp value less than 1 would indicate that more than _____ percent of produced units will not meet design specifications.
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Graph C has the tallest and narrowest line with endpoints at _____ and _____, well inside the LSL and USL.
Graph C has the tallest and narrowest line with endpoints at _____ and _____, well inside the LSL and USL.
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In Six Sigma Quality, the ______ monitors the output of a process to ensure that sample statistics are within the expected variation limits of the process.
In Six Sigma Quality, the ______ monitors the output of a process to ensure that sample statistics are within the expected variation limits of the process.
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In a bell-shaped curve, ______ percent of sample mean values fall within 3 sigma of the center line.
In a bell-shaped curve, ______ percent of sample mean values fall within 3 sigma of the center line.
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In the Xbar&R process, the range, R, is the difference between the ______ and smallest values.
In the Xbar&R process, the range, R, is the difference between the ______ and smallest values.
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The grand mean is calculated as the value of = (the ______ every x )/n.
The grand mean is calculated as the value of = (the ______ every x )/n.
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The mean range is calculated as the value of = (the ______ of the every R)/n.
The mean range is calculated as the value of = (the ______ of the every R)/n.
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Process control charts or _______________ process control (SPC) are tools used to monitor process output.
Process control charts or _______________ process control (SPC) are tools used to monitor process output.
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The process width is defined by a _______________ interval (usually 99 percent or 3σ).
The process width is defined by a _______________ interval (usually 99 percent or 3σ).
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A point outside the upper and lower limits on a process control chart indicates that the process may have _______________.
A point outside the upper and lower limits on a process control chart indicates that the process may have _______________.
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Process control charts identify when a process has deviated from its normal _______________ operation.
Process control charts identify when a process has deviated from its normal _______________ operation.
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When a process is 'out of control', the process operator should stop, _______________, and correct the process.
When a process is 'out of control', the process operator should stop, _______________, and correct the process.
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Study Notes
Six Sigma Quality
- Aims to achieve near quality perfection, with a statistical likelihood of non-defects of 99.99966% of the time.
Defects per Million Opportunities (DPMO)
- A metric used to describe the variability of a process.
- Requires three pieces of data: unit, defect, and opportunity.
- Formula: DPMO = (Number of defects / (Number of opportunities for error per unit × Number of units)) × 1,000,000
Six Sigma Methodology (DMAIC)
- Define: identify customers and their priorities, a project suitable for Six Sigma efforts, and CTQs (critical-to-quality characteristics).
- Measure: determine how to measure the process and how it is performing, and identify the key internal processes that influence CTQs.
- Analyze: determine the most likely causes of defects and identify the key variables.
- Improve: identify means to remove the causes of defects, confirm the key variables, and identify the maximum acceptance ranges of the key variables.
- Control: determine how to maintain the improvements and put tools in place to ensure that the key variables remain within maximum acceptance ranges.
Process Capability Analysis
- A tool for assessing the ability of a process to consistently meet or exceed a product's design specifications.
- Considers the tolerances allowed by product or service design specifications and the natural variability in the process.
- Formula: Cp = Specification width / Process width
Process Capability Analysis Examples
- Example 1: K Computers' medical equipment cart, where piping is cut internally and a scatter diagram shows a positive relationship between conveyor speed and cut length.
- Example 2: Deceptive Cp Value, where the process width and specification width are the same, but the center of the graph is not aligned with the design center, resulting in a Cp value that does not accurately reflect the process capability.
Adjusted Cp Metric (Cpk)
- Used to deal with non-centered process distributions.
- Formula: Cpk = Cp × (1 - K), where K is a correction term.
- Cpk is less than 1, indicating an unreliable process that cannot reliably meet design specifications.
Cpk, PPM, and Process Management
- Cpk values and their corresponding process implications:
- 0.50: Process is incapable, 100% inspection may be needed.
- 1.00: Process capable, normal sampling would be typical.
- 1.33: Process capable, normal sampling would be typical.
- 1.50: Process capable, no inspection may be needed.
- 2.00: Process is very stable, no inspection may be needed.
Process Control Analysis
- Process Control Charts (SPC) are used to monitor process output to detect changes.
- Intelligent systems plot and compare outputs to a set of limits for the upper and lower boundaries of the process width.
- Process control charts identify when a process has deviated from its normal operation.
Process Control Charts (Xbar&R)
- An example of Xbar & R: tracking hard disk seek times to ensure the process of building the disks is under control.
- Steps to create an Xbar & R chart:
- Collect data samples.
- Calculate the sample mean (x) for each sample.
- Calculate the range (R) for each sample.
- Calculate the grand mean.
- Calculate the mean range.
Quality Definitions
- Product quality is a product's fitness for consumption, which is determined by both design quality and conformance quality.
- Design quality measures how well a product's designed features match up to the requirements of a given customer group.
- Conformance quality measures whether a delivered product meets its design specifications.
Dimensions of Quality
- Performance: the degree to which a product meets or exceeds certain operating characteristics.
- Features: presence of unique product characteristics that supplement basic functions.
- Reliability: length of time a product performs before it must be repaired.
- Durability: length of product life or the amount of use one gets before a product deteriorates.
- Conformance: the degree to which a product meets its design specifications.
- Aesthetics: subjective assessment of a product's look, feel, sound, taste, or smell.
- Support/Responsiveness: competence of product support in terms of installation, information, maintenance, or repair.
- Perceived Quality (Reputation/Assurance/Empathy): subjective assessment based on image, advertising, brand names, reputation, or other information indirectly associated with the product's attributes.
Total Quality Management (TQM)
- An integrated strategy aimed at embedding awareness of quality, aiming for near quality perfection (the statistical likelihood of non-defects: 99.99966% of the time).
Six Sigma Quality
- Defects per Million Opportunities (DPMO): a metric used to describe the variability of the process, requiring three pieces of data: unit, defect, and opportunity.
- Six Sigma Methodology (DMAIC):
- Define: identify customers and their priorities, a project suitable for Six Sigma efforts, and critical-to-quality characteristics.
- Measure: determine how to measure the process and how it is performing, and identify the key internal processes that influence critical-to-quality characteristics.
- Analyze: determine the most likely causes of defects and identify the key variables.
- Improve: identify means to remove the causes of defects, confirm the key variables, and identify the maximum acceptance ranges of the key variables.
- Control: determine how to maintain the improvements and put tools in place to ensure that the key variables remain within maximum acceptance ranges.
Process Capability Analysis
- A tool for assessing the ability of a process to consistently meet or exceed a product's design specifications, considering tolerances allowed by product or service design specifications and the natural variability in the process.
- Cp = Specification width / Process width, where Cp is a measure of process capability.
Process Control Analysis (p Chart)
- A chart that plots the proportion of defectives in each sample, with the proportion of defectives (p) on the vertical axis and the sample number on the horizontal axis.
- The graph has the upper limit at 0.09 and the lower limit at 0.00, and p-bar at 0.0335.
- Interpreting Control Charts:
- Trends: successive points seem to fall along a line moving upward or downward.
- Runs: run of points that indicate systemic changes in process.
- Hugging: points appear so closely grouped that they seem to show no variation.
- Periodicity: plotted points show the same pattern of change over equal intervals.
Quality Management
- Hyundai's brand turnaround involved increasing the quality control team from 100 to 850 workers, instituting mandatory seminars, and involving the CEO in quality comparisons with rivals.
- Hyundai invested $30 million in a computer center to test electronic systems and made capital investments in problem areas.
Brand Turnaround at Hyundai - Results of Changes
- Hyundai's brand loyalty surpassed that of Honda and Toyota, with five Hyundai cars among the "Best Bets" for safety, reliability, and fuel efficiency.
- Genesis models made Hyundai a strong competitor in the luxury market, where excellent quality is imperative.
- In 2014, Hyundai placed first in the J.D. Power Initial Quality Study, with an average of 90 problems per 100 vehicles, 20% fewer problems than those found in European, Japanese, and American cars.
Six Sigma Quality
- Defects per Million Opportunities (DPMO) is a metric used to describe the variability of a process.
- DPMO requires three pieces of data: unit, defect, and opportunity.
- The formula for DPMO is:
Number of defects / (Number of opportunities for error per unit × Number of units) × 1,000,000
Six Sigma Methodology (DMAIC)
- Define: identify customers and their priorities, a project suitable for Six Sigma efforts, and CTQs (critical-to-quality characteristics).
- Measure: determine how to measure the process and how it is performing, and identify the key internal processes that influence CTQs.
- Analyze: determine the most likely causes of defects and identify the key variables.
- Improve: identify means to remove the causes of defects, confirm the key variables, and identify the maximum acceptance ranges of the key variables.
- Control: determine how to maintain the improvements and put tools in place to ensure that the key variables remain within maximum acceptance ranges.
Process Capability Analysis
- Process capability analysis is a tool for assessing the ability of a process to consistently meet or exceed a product's design specifications.
- Specification width (S) is the design specification for a product.
- Process width (P) is the actual range of outcomes generated by the production process.
- Cp is the ratio of the specification width to the process width.
- Cp =
USL - LSL / 6σ( Upper Specification Limit - Lower Specification Limit / 6 standard deviations)
Process Control Analysis
- Process control charts or statistical process control (SPC) are tools used to monitor process output to detect changes.
- Intelligent systems plot and compare outputs to a set of limits for the upper and lower boundaries of the process width.
- Process control charts identify when a process has deviated from its normal operation (when it is "out of control").
- Xbar & R is an example of process control analysis, where sample means and ranges are used to track the process.
Xbar & R
- Xbar & R is used to track the process of building hard disks and ensure that the seek times are under control.
- The process involves collecting data samples, calculating the sample mean and range, and calculating the grand mean and mean range.
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Description
This quiz covers the concept of Six Sigma quality and its relation to defects per million opportunities, including the measurement and calculation of DPMO.
