1. IENG 451 / 452 Exam Review: Six Sigma Philosophy Lectures 01 – 12
IENG Lecture 13
Exam Review:
Six Sigma Philosophy
Lectures 01 – 12
12/29/2017
IENG 451 Operational Strategies
(c) D.H. Jensen

2. Exam: Materials & Timing
On-Campus Exam is at LAB time in this room
Things to Bring:
Mechanical Pencil(s) & Eraser
Calculator
Engineering Notebook
Examination Process:
Arrive between 12:55 PM and 1:00 PM
Grab test gear, leave pack at back of room
Sit in front of a fresh exam, start exam at 1:00 PM
Complete exam with best answers possible
Return exam by 2:50 PM (exam must be in folder at 2:52 PM)
Quietly grab pack and stow test gear (keep your notebook)
Enjoy the refreshing absence of exam questions
12/29/2017
IENG 451 Operational Strategies

3. Exam: Format & Directions
Exam is 45 min. long, but may have 1 hr, 50 min.
Exam is 40 questions, and may consist of:
Multiple Choice
Short Calculations
Short Answer
Exam Directions:
Do NOT pull apart the exam booklet or answer sheet
Do NOT write in the exam booklet
Put ALL answers on exam answer sheet
Scratch paper is provided with the exam answer sheet
Choose the best answer
Make sure exam booklet is returned and answer sheet & scratch paper is in the folder by 2:52 PM
12/29/2017
IENG 451 Operational Strategies

4. Exam: Coverage & Topics
Exam covers Lectures 02 – 12, and portions of Rowlands text as covered in classes / labs
Lecture 02 – DMAIC Problem Solving:
DMAIC acronym
Project Team Approach
Membership
Time frame
Kaizen Approach
DMAIC process detail
Purpose
Outputs
Steps
Indicators for when to follow DMAIC process
12/29/2017
IENG 451 Operational Strategies

5. Exam: Coverage & Topics
Lecture 03 – Ideation:
Brainstorming
Purpose
Process
“NO” Rules
Fishbone Diagrams
Process (how to construct)
4 Ms and an E
Affinity Diagrams
Use to focus thinking
Multi-Voting
Use to move team forward
12/29/2017
IENG 451 Operational Strategies

6. Exam: Coverage & Topics
Lecture 04 – Quality Matters:
Definition
Fitness for Use or Reduction of Variability
Cost of (Poor) Quality
Myths
Cost per Good Part
Leverage: Savings & Productivity
Understanding Variation
Aspects of Process Variation
Independence and Central Limit Theorem
Normal Distribution
Converting to N(0,1) using z-statistic
Area under the Standard Normal curve
Yield or Defective Computations
Six Sigma
Motorola Six Sigma
12/29/2017
IENG 451 Operational Strategies

7. Exam: Coverage & Topics
Lecture 05 – Process Tools:
Process Capability – Cp
Meaning & Computation: Two Sided v. One Sided
Relation to Process Fallout
Recommended Minimum Ratios
Process Capability – Cpk
Relationship with Cp
Meaning & Computation
Process Capability – Cpm
SIPOC Diagrams
Acronym
Identifies the Whats
Keys (actions) for a SIPOC Diagram
Swim Lane Charts
Identifies the Whos
Construction of a Swim Lane Chart
12/29/2017
IENG 451 Operational Strategies

8. Exam: Coverage & Topics
Lecture 06 – Process Tools:
Value Stream Maps
Relationship with SIPOC and Swim Lane Diagrams
Use: AS-IS and TO-BE
Creating a VSM
Construction Steps
Typical Symbols
Typical Data Box information
Value-Added Concept
What is Value-Added
What is Non-Value-Added
What is Business Non-Value-Added
Value-Analysis (Time-Value-Map)
Addition to the bottom of the VSM
Steps to creation / addition
Meaning and use of the NVA to VA ratio
12/29/2017
IENG 451 Operational Strategies

9. Exam: Coverage & Topics
Lecture 07 – Voice of the Customer:
Voice of the Customer (VOC) & Data Gathering Methods
Relationship with Value & Types of Customers (perspectives)
VOC Data & Gathering Methods
Four Levels of Data
Sources of Data and Segmentation
General Requirements
Face-To-Face Interviews
Description & Uses
Mistakes to Avoid
Telephone Interviews
Surveys
12/29/2017
IENG 451 Operational Strategies

10. Exam: Coverage & Topics
Lecture 08 – Voice of the Customer:
Focus Groups
Description & Uses
Mistakes to Avoid
Point-Of-Use Observations
Analyzing the VOC
Reducing Risks and Identifying Features
KANO Analysis
Purpose (outcomes)
Steps, Responses, and Matrix
Meanings: Dissatisfiers, Satisfiers, and Delighters
CTQs
Acronym
Steps to develop CTQs
Good CTQ Characteristics
12/29/2017
IENG 451 Operational Strategies

11. Exam: Coverage & Topics
Lecture 09 – Data Collection:
Ishikawa’s Tools
Listing of the 7 Tools
Histogram
Two Purposes
Description & Construction
Pareto Chart
Description & Uses
Fishbone Diagram
Defect Concentration Diagram
Check List
Scatter Plot
12/29/2017
IENG 451 Operational Strategies

12. Exam: Coverage & Topics
Lecture 10 – Data Collection:
Data Collection Planning
Two Kinds of Data
10 Steps in a Data Collection Plan
Measurement Selection
Steps
Matrix Description & Construction
Stratification Factors
Diagram Description & Construction
Operational Definitions
Purpose
Sampling Concerns
Minimum Sample Size Calculation
Continuous Samples computations
Discrete Samples: Large & Small computations
12/29/2017
IENG 451 Operational Strategies

13. Exam: Coverage & Topics
Lecture 10 – Data Collection:
Measurement System Analysis: Gage R & R
Variability in Measurements
Total Variation
Product Variability
Gage Variability
Assessing Gage Capability
Repeatability
Reproducability
Process
Total Variance Computation
Product Variance Computation
Precision to Tolerance Ratio computation & Rule of Thumb
X and R chart Method Interpretation
12/29/2017
IENG 451 Operational Strategies

14. Exam: Coverage & Topics
Lecture 11 – Improvement Selection:
Improvement Idea Methods
Benchmarking
Sources for Data
Four Types of Benchmarking
Pros & Cons
Alignment with Management
Sources for Directions
Data for Financial Alignment
Economic Models for Justification
Identifying Cash Flows
NPW
EAW
Reviewing the Economic Models
12/29/2017
IENG 451 Operational Strategies

15. Exam: Coverage & Topics
Lecture 12 – Improvement Selection:
Improvement Selection Criteria
CTQs
Triple Constraint
Other Criteria
Developing Criteria & the Down-Select Process
Questions that might help
Steps for Down-Select
Decision Matrix
Steps (Matrix Construction)
Concerns
Pairwise Ranking
Steps
FMEA
Purpose & Stage Uses
12/29/2017
IENG 451 Operational Strategies

16. IENG 451 Operational Strategies
Questions & Issues
On-Campus exam is Thursday at LAB (providing a 2 hour exam period!)
Distance / On-line exam instructions were covered earlier in term (see Lecture 01)
instructor for ADA accommodations
12/29/2017
IENG 451 Operational Strategies
(c) D.H. Jensen