FINAL EXAM
Instruction
Answer all questions and submit your exam as an attachment to your Final Exam Assignments Folder.
Prefix your file name with your last name. You may submit your exam in more than one file and if you
do so, clearly label all your files with your name and in a way such that I can figure out which one is for
which question(s) or problem(s).
Prepare your answer file(s) in MS Word and or Excel. Please do not submit any PDF’s.
For Example, the problems (Part C of the exam) can be solved using MS Excel and show in details all the
formulas and calculations used to arrive to the answers. A) Please answer the following True or False questions (each worth 2 points)
1) Nonrandom variation can be the result of an operator error.
True _____ False____ 2) Empowerment means giving power to team members who previously had
little control over their jobs.
True ______ False______
3) Control charts can show if the process is producing good output
True ______ False______
4) Two items in parallel having a reliability of 0.90 have an overall system
reliability of 0.81..
True ______ False______
5) The lower control limit for a p-chart can be lower than 0.
True ______ False______
6) The stage of team development where the team becomes a cohesive unit and
interdependence, trust, and cooperation develop, is known as performing
True ______ False______
7) In QFD, an absolute weight for a customer requirement is calculated by
multiplying the customer importance score times the target value times the
sales point designation.
True ______ False____
1 8) A process capability of 2.00 or higher is Six Sigma.
True _____ False____
9) The first component of a complaint resolution process is contrition.
True ______ False______
10) It is not possible to be in control on the X-bar chart and out of control on the
R-chart for the same process at the same time
True ______ False______
B) Please answer the following multiple choice questions (each worth 3 points)):
1. A system is to be composed of 5 identical components in series. What is
the lowest reliability component that can be used in order to have an
overall system reliability of 0.90?
A.
B.
C.
D.
E. 2. 0.98
0.97
0.96
0.95
0.94 The Six in Six Sigma refers to the ________.
A. number of standard deviations from a specification limit to the mean
of a highly capable process
B. number of means from a specification limit to the standard deviation
of a highly capable process
C. number of variances from a specification limit to the mean of a
highly capable process
D. number of means from a specification limit to the variances of a
highly capable process
E) number of means from zero of a highly capable process 3. Reliability models assume statistical independence between failure
events. This means:
A. components do not fail
B. if one component fails, the entire system fails
C. parallel systems are unnecessary
2 D. the failure of one component does not influence another to fail
E. series systems are unnecessary
4. Graphical data analysis, hypothesis tests, and process modeling and
simulation are the tools used in the ________ phase of a Six Sigma
project
A. define
B. measure
C. analyze
D. improve
E. control 5. The process of examining competing technologies to produce a product
is known as ________.
A. robust design
B. concept design
C. parameter design
D. finish design 6. The final step in the self-assessment process described in the text is to:
A.
B.
C.
D.
E. 7. Off line experimentation is performed during the ________ phase of Six
Sigma.
A.
B.
C.
D.
E. 8. document findings
collect data
evaluate strengths and areas for improvement
develop improvement strategy
make a plan control
improve
analysis
identification
variation What is the Taguchi constant for a device that costs $400 to repair and a
tolerance of plus or minus 0.5 mm with a mean squared deviation from
the target of 0.3?
A.
B.
C.
D. 144
480
4444
1600
3 E. 9. 1111 Which of the following is true of nonrandom variation?.
A.
B.
C.
D. It is uncontrollable.
It is centered on a mean.
It occurs with a somewhat consistent amount of dispersion.
It results from a shift in a process mean or some unexpected
occurrence.
E. It results in a process that is repeatable.
10. What is the first step in a process improvement project?
A. creating a control chart
B. developing scatter plots
C. developing a histogram
D. creating a process map
E. setting up a check sheet C) Please respond to the following questions. Each question is worth 10 points:
1) A machine shop owner wishes to monitor the diameter of an engine
boring operation where the piston bore should be 4.25”. He obtains 8
samples of 5 and records the following data. Calculate the control limits
for X bar and R charts, plot the charts and indicate if the process is in
control.
1
5.1
4.4
4.7
4.9
4.9 2) 2
4.7
4.5
4.9
5.1
5.2 3
4.3
4.6
4.4
4.6
4.9 Sample #
4
5
4.6
4.6
4.4
4.3
5
4.7
4.9
5
4.7
4.7 6
4.8
4.3
4.8
5
4.3 7
4.9
5.1
4.5
4.6
4.7 8
4.3
4.8
5
4.7
5.2 The diameter of a mason jar is 3 inches but can be as large as 3.03 inches and as small as 2.97
inches. If the process has a grand mean of 3.01 inches and a standard deviation of 0.02 inches.
What is the probability of producing bad product?
4 3) A project manager at System 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 25000 lines of code.
Please use the data to find the functional relationship of the coding time to the
program size and estimate the number of days it would take to code the system.
Size in 1000 lines
of code (KLOC)
Number of days to code Module
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 5 4) 21 195 75 22 190 77 23 182 69 24 152 65 25 174 69 For the above problem plot a histogram of module size in this
program. 5) A product is made up of two subsystems in parallel. Subsystem one consists of ten
elements in series each with a failure rate of 1/100. The second subsystem consists of
5 elements in series each with a failure rate of 1/200. What is the overall reliability of
the system? 6
