IENG 451 / 452 Exam Review: Six Sigma Philosophy Lectures 01 – 12 IENG 451 - Lecture 13 Exam Review: Six Sigma Philosophy Lectures 01 – 12 12/29/2017 IENG 451 Operational Strategies (c) 2016 D.H. Jensen

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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) E-mail instructor for ADA accommodations 12/29/2017 IENG 451 Operational Strategies (c) 2016 D.H. Jensen