1) Please explain the intention of Six Sigma.

i. to identify and eliminate causes of manufacturing defects within large-scale

industrial projects.
ii. is using a business improvement methodology to make the process as constant as
possible.
iii. is to implement a process, which systematically gets rid of inefficiency and defects.
iv. use Six Sigma to improve the processes, which help bring about positive changes in
the organization.
v. Reduces the process cost by reducing variation and opportunities of errors.
vi. Defines variation inherent in any process. It is statistical representation for what for
what many experts called a perfect process.

2) What is the Cause-Effect-Diagram of Ishikawa?

i. Also known as Ishikawa diagram by its inventor name. and it is one of 7 quality tools.
ii. It is used to find out multiple root causes of a single problem. the fish-bone diagram is not
just limited to finding a root cause in a single stream. The fish-bone diagram helps to find the
root cause in multiple streams / multiple areas. The fish-bone diagram is suitable for solving
complex problems.
iii. For using fishbone diagram, steps are as below.
I. Define Clear Problem Statement.
II. Team Formation.
III. Brainstorming.
IV. Analyse the problem.
V. Find out solutions of problem.
3) What is the idea of the Deming cycle PDCA?
i. PDCA cycle is a continuous quality improvement model, consist of four repetitive
steps for continuous improvement and learning.
ii. It involves systematically testing possible solutions, assessing the result and
implementing the once
iii. PLAN: plan ahead for change. Analyse and predict the results. Identify your problem.
DO: execute the plan, taking small steps in controlled circumstances. Test solution.
STUDY: check, study the results.
ACT: take action to standardize or improve the process, and implementation of best
solution.

4) What is the difference between Regression and Correlation?

Correlation Regression

i. It is statistical Measure which i. It describes, how independent

determines relationship variable is numerically related to
between 2 variables. dependent variable.
ii. Represent Linear relationship ii. Its usage is to fit a best line and
between two variables. estimate one variable on basis of
iii. No difference in both variables, another variable.
rxy=ryx. iii. Both variables are different, bxy=byx.
iv. It is relative measure. iv. It is absolute measure.
v. It does not imply cause and effect v. It indicates the cause-and-effect
relationship. relationship.
vi. It has a limited application. vi. It has a wider application.
 5) Why are DOE´s (Design of experiments) useful? Can you explain one DOE method in detail?
i. Design of Experiments (DOE) is a branch of applied statistics focused on using the scientific
method for planning, conducting, analysing and interpreting data from controlled tests or
experiments. DOE is a mathematical methodology used to effectively plan and conduct
scientific studies that change input variables (X) together to reveal their effect on a given
response or the output variable (Y). In plain, non-statistical language, the DOE allows you to
evaluate multiple variables or inputs to a process or design, their interactions with each
other and their impact on the output. In addition, if performed and analysed properly you
should be able to determine which variables have the most and least impact on the output.
By knowing this you can design a product or process that meets or exceeds quality
requirements and satisfies customer needs.
ii. DOE allows the experimenter to manipulate multiple inputs to determine their effect on the
output of the experiment or process. By performing a multi-factorial or “full-factorial”
experiment, DOE can reveal critical interactions that are often missed when performing a
single or “fractional factorial” experiment. By properly utilizing DOE methodology, the
number of trial builds or test runs can be greatly reduced. A robust Design of Experiments
can save project time and uncover hidden issues in the process. The hidden issues are
generally associated with the interactions of the various factors. In the end, teams will be able
to identify which factors impact the process the most and which ones have the least
influence on the process output.

6) What is the idea of the Analysis of Variance (ANOVA)? Please give an example of using it.

i. Analysis of Variance, or ANOVA for short, is a statistical test that looks for significant
differences between means on a particular measure. For example, say you are interested in
studying the education level of athletes in a community, so you survey people on various
teams. You start to wonder, however, if the education level is different among the different
teams. You could use an ANOVA to determine if the mean education level is different among
the softball team versus the rugby team versus the Ultimate Frisbee team.

ii. Key Takeaways: Analysis of Variance (ANOVA)

• Researchers conduct an ANOVA when they are interested in determining whether two
groups differ significantly on a particular measure or test.
• There are four basic types of ANOVA models: one-way between groups, one-way repeated
measures, two-way between groups, and two-way repeated measures.
• Statistical software programs can be used to make conducting an ANOVA easier and more
efficient.

7). Please give some aspects of the history of Quality Management.?

i. Till 19th century, Manufacturing in the industrialized world tented to follow this
craftsmanship model.
ii. After that factory system with focus on product inspection was started in Great Britain with
changes by American in predominant production method in 1800.
iii. In 1900s, with united states many European Countries started for adopting the quality
control concept by inspecting goods before sale after which the terms like quality
supervisors, audits were come into the factory system.
iv. After the world war II, Quality gained more attention, that is why solving of problems
without compromising product safety, the arm forces began to use sampling inspection to
replace unit by unit inspection.
 v. The beginning of 20th century marked the inclusion of process in quality practices, then with
the help of Walter Schewart foundation for control charts and quality tools was possible.
vi. The Deming became a proponent of Schwharts SQC Method and later the leader of quality
movement in Japan & US.
vii. After that, japans Stretegies with the help of Demings & Juran represented the “Total
Quality” approach.
viii. Japanese manufacturing focussed on all organizational process rather only focusing on
product from which the concept of “Total Quality Management” was discovered.
ix. For Settling the standardization, the concept like ISO 9000, ISO 9001 series of quality
management, Motorolas Six Sigma for minimization of defects etc. was developed to
improve overall structure of organization.
8) What are the 7 Muda? Please describe one of it more in detail.
i. MUDA is Japanese word that means “waste”. It describes the concept of being idle.
ii. MUDA is a non-value-added task within the process.
iii. The Concept that MUDA. Must be eliminated in a process is a driving concept of the TOYOTA
production system and lean manufacturing.
iv. MUDAS are TIMWOOD (Transport, Inventory, Motion, Waiting, Over Production, Over
processing, Defects)

9) Can you explain the acronym SIPOC?

i. SIPOC (Supplier-Inputs-Processes-Outputs-Customers).
Supplier – Who supplies the process inputs? (Consumer, retail cust., SAP CRM system, SAP )
Inputs- What inputs are required? (Orders, Fax order, Customer calls & emails, Order status)
Processes- What are the major steps in the process?
Outputs- What are the process outputs? (Orders entered, close customer inquiries)
Customers- Who receives the outputs? (Consumer, Retail customer, Mature product
engineering).
ii. By using this method, it is possible to quickly obtain a superior overview of all the main
elements of a process to be investigated, even before more in-depth details are worked out.
iii. SIPOC is a very simple and at the same time quite effective method, which can also be used in
different situations in the lean context.
iv. The SIPOC method is not about performing a detailed process analysis, but only about
obtaining a rough overview.
v. SIPOC is a method to describe the transformation process within a company that offers
product on service.
vi. It is a tool for process improvement.

10) Please explain the differences between Management and Leadership?

i. Leadership – Involves a group of people by leading and management need only be
concerned with responsibility for things.
ii. Leadership involves creating new vision and aims, making new rules and policies, creating
new job roles, problem anticipation, planning, and organizing succession., etc.
iii. Management Involves implementing tactical actions, detailed budgeting, measuring, and
reporting performance, applying rules and policies.
11) Please explain, how a Box Plot diagram can be plotted.
i. It is a method of Visualization of data.
ii. It is time independent representation of data which shows some special features. It is robust
and shows asymmetric outline.
iii. Usually, the BOX plot is displayed vertically.
iv. The box is bordered downwards / upwards: in each case 25% of the values lie below / above
the median. The two quartiles together lead to 50% of the values in the box
12) Why a FMEA is used? Please explain in some terms the procedure of a FMEA (Failure mode and
effect analysis?
i. Failure mode and effect analysis is a structured approach to discovering the potential failure
that may exist within the design of product or process.
ii. Failure modes are the ways in which a process can fail, effects one the ways that these
failures can lead to waste, defects harmful outcomes for customer.
iii. There are 2 broad categories of FMEA- 1) Design FMEA and 2) Process FMEA.
iv. FMEA also known as PPA (Potential Problem Analysis).
v. FMEA is a technique, which helps to identify the potential problems, helps to identify the
preventive action, helps to identify the contingency action that you take.
13) Give some aspects, how Risk Management can be achieved.?
i. Risk Management is a process that allows us to systematically consider risk while making
decision. In almost every facility, considering potential risk already a part of natural decision-
making process.
ii. The identification, evaluation and reduction of risk should ultimately be considered a
consumer safety activity.
RPN (Risk Priority Number) is a numeric assessment of Risk assigned to a process or step in a process
as part of FMES. The risk management team assigns each failure mode numeric values that quantify
the likelihood of occurrence, the likelihood of detection, and severity of impact. All variables are
important in evaluating the risk of the process or the product. While some RPNs may indicate an
issue may occur that could impact a small percentage of finished products, others can identify high-
risk safety impacts that may justify a redesign to the product itself.
14) What are the 7 Principles of Quality Management according to the ISO 9001?
i. Customer Focus: - Organisations depend on their customers and therefore should
understand current and future customer needs, should meet customer requirements, and
strive to exceed customer expectations.
ii. Leadership: - Leaders establish unity of purpose and direction of the organisation. They
should create and maintain the internal environment in which people can become fully
involved in achieving the organisation’s objectives.
iii. Engagement of People: - People at all levels are the essence of an organisation and their full
involvement enables their abilities to be used for the organisation’s benefit.
iv. Process Approach: - A desired result is achieved more efficiently when activities and related
resources are managed as a process.
v. Improvement: - Continual improvement of the organisation’s overall performance should be
a permanent objective of the organisation.
vi. Evidence Based Decision Making: - Effective decisions are based on the analysis of data and
information.
vii. Relationship Management: - An organisation and its interested parties (including suppliers)
are interdependent, and a mutually beneficial relationship enhances the ability of both to
create value.
15) Please explain the Pareto principle
i. Also called 80-20 rule, says that 20% of causes lead to 80% of defects. The pareto principal
1st suggest by joseph Juran. The Principle is common in various circles. Business
professionals commonly state that 80 % of sales comes from 20% of customer.
ii. This principle is critical to six sigma, because it applies that a few inputs creates more impact
than all of their inputs. Pareto chart is one of the basic tools of quality control. It is used to
determine the most frequent defect complains.
iii. It is usual tool used to analyse data sets related to specific problem on issue. Pareto Chart
has vertical bars descending from left to right and line that represent a cumulative curve.
The bar that has max value falls to left & that has lowest value falls to right into right.
16) What are the main objectives behind the standard ISO 9001?

17) Please describe the Boot Strapping method.

i. Bootstrapping is a test or metric that relies on random sampling with replacement of data
set.
ii. Suppose we have n=10 & n=50 readings & we want to say something reasonable about
readings.
iii. Actual form of distribution is not known to us, so the mean value “X” is calculated accident
free for the variance “S “, we use the formula for standard deviation. If we now state, the
process position with X+- 3S, the uncertainty remains & we don’t know how S was
determined.
iv. We use bootstrapping method to determine how exactly we specify the variance “S” .
Bootstrapping resamples the original dataset with replacement many thousands of times to
create simulated datasets. This process involves drawing random samples from the original
dataset. Here is how it works:

I. The bootstrap method has an equal probability of randomly drawing each original
data point for inclusion in the resampled datasets.
II. The procedure can select a data point more than once for a resampled dataset. This
property is the “with replacement” aspect of the process.
III. The procedure creates resampled datasets that are the same size as the original
dataset.
v. The process ends with your simulated datasets having many different combinations of the
values that exist in the original dataset. Each simulated dataset has its own set of sample
statistics, such as the mean, median, and standard deviation. Bootstrapping procedures use
the distribution of the sample statistics across the simulated samples as the sampling
distribution.
vi. Resampling involves reusing your one dataset many times. It almost seems too good to be
true! In fact, the term “bootstrapping” comes from the impossible phrase of pulling
yourself up by your own bootstraps! However, using the power of computers to randomly
resample your one dataset to create thousands of simulated datasets produces meaningful
results.
vii. To understand how it works, keep in mind that bootstrapping does not create new data.
Instead, it treats the original sample as a proxy for the real population and then draws
random samples from it. Consequently, the central assumption for bootstrapping is that the
original sample accurately represents the actual population.

18) What is the idea of Lean Management?

Lean was developed as a concept for reducing waste in manufacturing environment.
Lean process management can be applied to a process that involves creation of goods &
services. Lean provides waste removal tool. One of the lean's continuous improvement tool is
"KAIZEN" Change for better. The purpose of Kaizen is to eliminate waste and create more
value for the customers. Lean process management helps to increase producation and
reduce costs for their departments. Lean process management can be deployed within a
project environment or in daily production like 6 sigma.
19) Please explain the terms: normal distribution and standard deviation?

i. The driving goal of six sigma is to reduce the defects. By reducing defects, teams can
increase productivity, decrease overall cost, increase customer satisfaction, and create
maximum profit. One idea inherent in the six-sigma methodology is that variance is the root
of many defects.
ii. Standard deviation is a statistic that describes the amount of variation in a measured
process characteristic.
iii. It shows how much an individual measurement is expected to deviate from mean to
average.
Normal Distribution
iv. Normal Distribution curve shows how data is plotted on frequency diagram.
v. An introduction to the normal distribution, often called the Gaussian distribution.
vi. is a probability distribution that is symmetric about the mean, showing that data near the
mean are more frequent in occurrence than data far from the mean. In graph form, normal
distribution will appear as a bell curve.
vii. Characteristics: - a) Concentration of the values around the mean b) Symmetry of value
around the mean position. C) It describes width in width value scattered.
viii. normal distribution is the proper term for a probability bell curve.
ix. In a normal distribution the mean is zero and the standard deviation is 1. It has zero skew
and a kurtosis of 3.
x. Normal distributions are symmetrical, but not all symmetrical distributions are normal.
xi. In reality, most pricing distributions are not perfectly normal.

20) What is a histogram? Please give an example.

i. Histogram is a graphical representation of a frequency distribution which is a summary of

variation in a product or process.
ii. Uses Of Histogram: - 1) To know the pattern of variation. 2) To assess states of control 3) To
assess conformance to specifications 4) To assess spread or variation with reference to
specification. 5) To assess process capability. 6) To get clues for bringing process under
control - whether to shift mean or to reduce variation or both. 7) To get clues for possible
assignable causes for observed variation - mixture of lots, suppliers, instruments
/measurements errors, bias of written results etc.
iii. Histogram helps six sigma team to understand how the spreadsheet distribution data is
shaped and where the centre of data lies.
iv. Centre is always the average of data process.
v. Histogram shows the range i.e the variation between highest and lowest point of data.
vi. Its data provide the information about where the data is centralized.

21) What is control Chart?

i. Control chart is a graphical device to aid in process control.

ii. It consists of a graph with a central line denoting the target value control limit” and “Limit
control limit” and two limit lines on either side of the central line called “Upper
iii. Quality measured periodically is plotted on the chart and status of control assessed.
iv. The control chart was first proposed by Dr.Walter A Shewhart, an engineer in the Bell
Telephone laboratories, USA with a view to eliminate abnormal variation.
v. It is used to find out weather process is stable or unstable.
vi. Used for controlling outgoing process by finding correcting problems as they occur.
vii. When predicting the expected range of outcomes from process.
It consist of a graph with a central line denoting the target value and two limit lines in either side
of the central line called "Lower control limit" and "Upper control limit".
22) What is six Sigma?

i. It is methodology for process improvement.

ii. It is statistical concept which defines variation inherent in any process.
iii. Six Sigma Reduces the process cost by reducing variation and opportunities for error.
iv. In a six-sigma process, there are only 3.4 defects per million opportunities, which means
99.9999% of the products from six sigma process are without defects.
v. Six Sigma Reduces the time, Defects, Variability.
vi. It increases customer Loyalty.
vii. It improves employee morale. DMAIC
viii. 2 major methodology of 6 Sigma -
DMADV
ix. DMAIC – Define – Measure – Analyse – Improve – Control.
x. DMADV- Define- Measure- Analyse- Design- Verify.
xi. DMADV used when creating a new product or service from scratch. & it is also called DFSS.
xii. Six Sigma Principle: -
1- Customer Focus Improvement.
2- Continuous Process Improvement.
3- Reducing the variation.
4- Removing the waste.
5- Equipping the people.
6- Controlling the process.

23) What is cumulative sum? How does it work?

i. Cumulative sum is sequential analysis technique.

ii. It is typically used for monitoring change detection.
iii. It is used for quality and process analysis helps to show change in process.
iv. It is defined as cumulative sum from deviation to the mean.
v. It shows the temporal dependence and help to detect the time of deviation.
vi. Cu Sum can be calculated. Σi = ai -µ + Σi -1

24) JIT (Just In Time): -

i. Another Lean concept generated from TOYOTA.

ii. Produce output “Just In time “or as needed by customer.
iii. Customer was the person or process who required output. i.e., End customer and for other
time, customer will be different employee or process or organization.
iv. 1st M/c supply only part which is required to 2nd m/c. i.e., If M/C 1st produce a part in one
minute then 2nd M/C should have a C/T a 1 min.
v. Difficult to obtain ideal level of machines, but most companies try to come close as possible.
vi. Using predictive analysis, companies attempt to estimate how many of each product will sell
before they produce those products.

25) What is Cp & Cpk? (Capability indices)

i. Cp and Cpk are called Process Capability. Cp, and Cpk are used for Process Capability.
ii. Generally, you use this when process is under statistical control.
iii. Cp and Cpk measure how consistent you are to around your average performance.
vii. The ‘k’ stands for ‘centralizing factor.’ The index takes into consideration the fact that your
data is maybe not centered.
Process capability is calculated by dividing the sigma level by 3. A process capability of
1.33 = sigma level 4 which is the minimum level at which the customer will be satisfied.
They are used tp define the ability of process to produce a product that meets the
requirements.
viii. Cpk tells us what a process is capable of doing in future, assuming it remains in a state of
statistical control.
iv. Cpk is a measure to show how many standard deviations the specification limits are from the
centre of the process. On some processes you can do this visually. Others require an
equation.

26) IATF (International Automotive task force).

i. The IATF (International Automotive Task Force) is a "purpose-specific" working group

composed of representatives of mostly North American and European
car manufacturers and automobile associations and deals with the harmonisation
(unification) of standards (standards) to improve product quality for automotive
customers.
The IATF was founded to carry out the following tasks:[1]
ii. Development of an international consensus on the basic QM system requirements –
primarily for application by participating companies, direct suppliers (Tier 1 suppliers) of
production materials, spare parts and machining services (e..B: heat and surface treatment
and coating). However, the requirements developed are also to be made available to other
interested users in the automotive industry.
iii. Development of guidelines and procedures for the worldwide application of a uniform 3rd
Party certification procedure.
iv. Provide an appropriate training programme to support IATF 16949 requirements and the
appropriate certification process.
v. Develop official relationships with relevant organisations to support the objectives of the
IATF.

27) Why we need Standards?

i. A standard is a document that sets out requirement for a specific item, materials,
component, system on service or describe in detail particular method on procedure.
ii. Standards Facilitates internationals trade by ensuring compatibility and interoperability of
component, product, and services. They bring benefits to the business and consumers in
terms of reducing costs, enhancing performance, and improving safety.
iii. Standards are developed and defined through a process of sharing knowledge and building
consensus among technical experts nominated by interested parties and stakeholders
including business, consumers, and environmental group, among others.
iv. The formal definition of standards is a document established by consensus and approved
by recognised body, that provides for common and repeated use rules, guidelines or
characteristics for activities or their results aimed at achievement of the optimum degree of
order in given context.

28) Quality Management System?

i. Quality is a fitness for use or Fulfil the requirements of customer or Conformance of

requirement in terms of people, cost, machine & Customer.
ii. QM system is act of planning controlling and directing the degree of excellence.
iii. QM focus on organization process, & continuous improvement.
iv. The ISO 9000 and ISO 9001 are guide for implementing the QMS, so if organization wants to
deliver the requirement of ISO 9001 standard.
29) Six Sigma Structure: -

i. Yellow Belt – Green Belt – Black Belt – Master Black Belt – Champions.
ii. Yellow Belt -
I. Part Time team member.
II. Provide supporting Role.
III. Helps in data collection, validation, monitoring effectiveness.
IV. Basic Understanding of Analytical tools.
i. Green Belt: -
I. Part time team member.
II. Drives fewer complex projects.
III. Understand basic working knowledge for lean six sigma project.
IV. Worker under guidance of black belt.
ii. Black Belt: -
I. Generally full time person for lean six sigma projects & derive complex projects.
II. Train and educate Green Belts / Yellow Belts.
III. Communicate with Champion.
iii. Master Black Belt: -
I. Assistant & advisor to champions.
II. Support black belt.
III. Monitors & removes bottleneck.
IV. Spread expertise about lean six sigma’s in the organization.
iv. Champion: -
I. Leader of organization.
II. Sponsor of the project.
III. Promotes & support projector with resources.
IV. Takes decision on bottleneck.