Part A.
True/False
1) Brainstorming is a fundamental tool of problem solving
2) A process is capable if the variations fall within +- 3 standard deviation
3) Random variationsfall outside the control limits.
4) Control charts are used to determine if there are special cause variation in the process.
5) 3 items in parallel, each having a reliability of 0.90 have an overall system reliability of 0.999.
6) nP chart is used when the number of defects per unit is fixed at n
7) A process in control may produce unacceptable output.
8) A Six Sigma process must have a process capability index of 6.
9) For a Normally distributed process the control limits are + - 3 times the standard deviation
10) A Control Chart is a Trend Chart (or Run Chart) that has control limits
Part B.
1. Which of the following tools are used to get the shape of the distribution.
A) Matrix diagram
B) Histogram
C)Affinity Diagram
D) Check sheets
E) Process map
2. Which of the following tools are used to find the relationship between two variables?
A) Process Map
B) Fishbone diagram
C) Pareto Chart
D) Scatter plot
E) Control chart
3. Which of the following is true of special cause variation?
A) It is uncontrollable.
B) It is centered around the mean.
C) It is inherent in the process.
D) All of the above.
E) None of the above
4. A true 3 Sigma Process should not have more than _______defects per million opportunities
A. 6,210
B. 3.4
C. 2700
D. 45500
5. An R chart is used to monitor __________.
A. Variation of the Mean
B. Process Dispersion
C. Trend in mean value
D. Trend in standard deviation
Part C
1) 97. 1) A product is made up of two subsystems in series. The first subsystem consists of 20 components in series. The second subsystem consists of 3 components in parallel. The components in subsystem 1 are all of the same design and each has a 1/10,000 chance of failure. The parallel components each has a 3/10,000 chance for failure. What is the overall reliability of the system?
2) A quality control engineer monitors the quality of a cylinder production line. He regularly selects a sample of 5 units and measures the diameters. The specification requires the diameter to be 6 inches plus/minus 0.1 inch. The following is a record of the measurements.Is the production process in control? Please use X bar and R charts to make an assessment.
|
Sample
|
item 1
|
item 2
|
item 3
|
item 4
|
item 5
|
|
1
|
6.10
|
6.15
|
5.35
|
5.98
|
5.95
|
|
2
|
6.35
|
6.02
|
6.20
|
6.10
|
5.70
|
|
3
|
5.85
|
5.90
|
6.20
|
6.12
|
6.08
|
|
4
|
6.00
|
5.80
|
5.70
|
6.04
|
6.17
|
|
5
|
6.15
|
5.60
|
6.25
|
5.99
|
6.01
|
|
6
|
6.13
|
6.05
|
5.89
|
6.00
|
5.87
|
|
7
|
5.88
|
6.03
|
5.76
|
6.1 3
|
6.00
|
|
8
|
6.12
|
5.45
|
6.15
|
6.04
|
5.91
|
3) A customer relationship manager decided to track customer complaints as part of his ongoing customer satisfaction improvement program. After collecting data for two months, their check sheet appears as follows:
|
Type of Problem
|
Frequency
(number of times)
|
|
Call went to voice mail
|
8
|
|
Items damaged when received
|
21
|
|
Literature not in the box
|
9
|
|
Parts missing
|
13
|
|
Unit not working
|
2
|
|
Delivery was late
|
3
|
Construct a Pareto chart including the cumulative % frequency.What is the cumulative percentage of the two leftmost bars?
4) A project manager at Global Design Corporation has collected the following data on the size of software programs and the length of programming time. The company is bidding on a new system that is estimated to consist of 250,000 lines of code. Use the data to find the correlation function of coding time to the program size and estimate the number of days it would take to code the system.
|
Module
|
Size in 1000 lines of code (KLOC)
|
Number of days to code
|
|
1
|
160
|
68
|
|
2
|
158
|
66
|
|
3
|
148
|
70
|
|
4
|
135
|
59
|
|
5
|
178
|
72
|
|
6
|
170
|
68
|
|
7
|
158
|
64
|
|
8
|
138
|
65
|
|
9
|
200
|
70
|
|
10
|
195
|
68
|
|
11
|
189
|
65
|
|
12
|
173
|
68
|
|
13
|
159
|
70
|
|
14
|
163
|
71
|
|
15
|
150
|
66
|
|
16
|
140
|
65
|
|
17
|
206
|
73
|
|
18
|
144
|
64
|
|
19
|
157
|
70
|
|
20
|
183
|
74
|
|
21
|
195
|
75
|
|
22
|
190
|
77
|
|
23
|
182
|
69
|
|
24
|
152
|
65
|
|
25
|
174
|
69
|
5) Describe the Sources of Team Conflict
6) Describe the 5 principles of Lean