Six Sigma Fundamentals & Tools Flashcards

Flashcards covering key concepts, tools, metrics, and methodologies from Six Sigma Fundamentals, Lean, DMAIC/DMADV, and related quality tools.

What is the main purpose of Six Sigma?

Improve quality, increase efficiency, enhance customer satisfaction, reduce costs, foster data-driven decisions, and promote continuous process improvement (DMAIC).

What does DMAIC stand for?

Define, Measure, Analyze, Improve, and Control – the core improvement cycle for existing processes.

Define DMADV and when is it used?

Define, Measure, Analyze, Design, Verify – used for creating new processes or products.

What is SIPOC in process analysis?

SIPOC stands for Suppliers, Inputs, Process, Outputs, and Customers; a high-level map of a process.

What does VoC stand for and how is it used?

VoC stands for Voice of the Customer; it captures customer needs and expectations to guide quality work.

What is CTQ in Six Sigma?

Critical to Quality; the key measurable characteristics derived from the Voice of the Customer.

Name two common elements of a Six Sigma Project Charter.

Problem Statement and Goals/Objectives (SMART) are core elements often included.

What does DPU mean in Six Sigma metrics?

Defects Per Unit – total defects divided by total units.

What does DPMO stand for?

Defects Per Million Opportunities – a standard defect-rate metric.

What is RTY and how is it calculated?

Rolled Throughput Yield; product of yields at each process step.

List the 7 Basic Quality Tools.

Fishbone (Ishikawa) Diagram, Check Sheet, Histogram, Pareto Chart, Scatter Diagram, Flowchart, Control Chart.

What are the 5S steps in order and their meanings?

Seiri (Sort), Seiton (Set in Order), Seiso (Shine), Seiketsu (Standardize), Shitsuke (Sustain).

What is 5 Whys analysis used for?

A root-cause analysis technique that asks 'Why?' repeatedly to identify underlying causes.

What is Kaizen in Lean Six Sigma?

A philosophy of continuous, incremental improvement involving all employees.

What is PDCA and how does it differ from PDSA?

PDCA stands for Plan-Do-Check-Act; PDSA stands for Plan-Do-Study-Act (Study emphasizes learning results).

What is a Control Plan?

A detailed document outlining how to maintain process improvements, including measures and ownership.

What is a Control Chart and its purpose?

A graph to monitor process performance over time and determine if the process is in control using control limits and a central line.

Differentiate between Control Limits and Specification Limits.

Control Limits are statistical bounds of the process; Specification Limits are customer/regulatory requirements.

What are p-charts and c-charts used for?

p-charts track the proportion of defectives; c-charts track the count of defects.

What is the difference between Common Cause and Special Cause variation?

Common cause is inherent, stable variation; Special (assignable) cause is identifiable and requires investigation.

What is the Z-score formula?

Z = (X − μ) / σ.

What is the difference between descriptive and inferential statistics?

Descriptive statistics summarize a sample; inferential statistics make predictions about a population from the sample.

What is the mean formula?

Mean x̄ = (Σ xi) / n.

What is the range formula?

Range = max(xi) − min(xi).

What does the table mapping DPMO to Sigma levels show (with 1.5 Sigma shift)?

It shows the DPMO values corresponding to sigma levels; e.g., at 3.0 sigma, DPMO ≈ 66,807 with the 1.5 sigma shift.

What is FMEA and its main components?

Failure Modes and Effects Analysis; components include Failure Modes, Severity, Occurrence, Detection, and Risk Priority Number (RPN).

What is the formula for RPN?

RPN = Severity × Occurrence × Detection.

What is Measurement System Analysis (MSA) and its components?

MSA evaluates the measurement system; key components are Operator, Measuring Instrument, Procedures, Environment, and Interaction Effects.

What are the main components of MSA beyond instruments and operators?

Procedures, Environment, and Interaction Effects.

What are k a few Lean basics like 5S and Gemba?

5S stands for Sort, Set in Order, Shine, Standardize, Sustain; Gemba refers to the real place where value is created (factory floor).

What is Yokoten in Lean terms?

Sharing best practices across departments and teams.

What is Plan-Do-Check-Act (PDCA) primarily used for?

A cycle for continuous improvement, foundational in Lean and Six Sigma.

What is the purpose of Value Stream Mapping (VSM) in Lean?

To analyze and design the flow of materials and information required to bring a product or service to a customer.

What is the purpose of a Gate Tollgate in DMAIC?

End-of-phase reviews to evaluate progress and decide whether to move to the next phase.