Term
| Juran defined “breakthrough” as |
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Definition
| the accomplishment of any improvement that takes an organization to unprecedented levels of performance. |
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Term
| “Six sigma” represents a quality level of |
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Definition
| at most 3.4 defects per million opportunities (dpmo). |
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Term
A six sigma quality level corresponds
to a process variation equal to half of the design tolerance while allowing the mean to shift as much as |
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Definition
| 1.5 standard deviations from the target. |
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Term
| Although originally developed for manufacturing in the context of tolerance-based specifications, the Six Sigma concept has been |
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Definition
| operationalized to apply to any process and has come to signify a generic quality level of at most 3.4 defects per million opportunities. |
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Term
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Definition
Define
Measure
Analyze
Improve
Control |
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Term
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Definition
Describe the problem in operational terms
Drill down to a specific problem statement (project scoping)
Identify customers and CTQs, performance metrics, and cost/revenue implications |
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Term
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Definition
| Key data collection questions |
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Term
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Definition
Focus on why defects, errors, or excessive variation occur
Seek the root cause
5-Why technique
Experimentation and verification |
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Term
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Definition
Idea generation
Brainstorming
Evaluation and selection
Implementation planning |
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Term
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Definition
Maintain improvements
Standard operating procedures
Training
Checklist or reviews
Statistical process control charts |
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Term
| Types of Quality Problems |
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Definition
Conformance problems
Efficiency problems
Unstructured performance problems
Product design problems
Process design problems |
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Term
| Key Factors in Six Sigma Project Selection |
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Definition
Financial return, as measured by costs associated with quality and process performance, and impacts on revenues and market share
Impacts on customers and organizational effectiveness
Probability of success
Impact on employees
Fit to strategy and competitive advantage |
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Term
Although we view process improvement
tools and techniques from the perspective of Six Sigma, it is important to understand |
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Definition
| that they are simply a collection of methods that have been used successfully in all types of quality management and improvement initiatives |
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Term
| The “Seven Quality Control Tools” |
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Definition
Flowcharts
Check sheets
Histograms
Cause-and-effect diagrams
Pareto diagrams
Scatter diagrams
Control charts |
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Term
| A flowchart or process map |
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Definition
| identifies the sequence of activities or the flow of materials and information in a process. |
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Term
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Definition
| show the performance and the variation of a process or some quality or productivity indicator over time in a graphical fashion that is easy to understand and interpret |
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Term
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Definition
| special types of data collection forms in which the results may be interpreted on the form directly without additional processing. |
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Term
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Definition
| one in which the characteristics observed are ordered from largest frequency to smallest. |
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Term
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Definition
| a histogram of the data from the largest frequency to the smallest. |
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Term
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Definition
Supplies the data to confirm a hypothesis that two variables are related
Provides both a visual and statistical means to test the strength of a relationship
Provides a good follow-up to cause and effect diagrams |
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Term
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Definition
| the elimination of waste in all forms, including defects requiring rework, unnecessary processing steps, unnecessary movement of materials or people, waiting time, excess inventory, and overproduction. |
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Term
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Definition
| seiri (sort), seiton (set in order), seiso (shine), seiketsu (standardize), and shitsuke (sustain). |
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Term
| All Six Sigma projects have three key characteristics: |
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Definition
| a problem to be solved, a process in which the problem exists, and one or more measures that quantify the gap to be closed and can be used to monitor progress. |
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Term
| Six Sigma Metrics in Services |
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Definition
Accuracy
Cycle time
Cost
Customer satisfaction |
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Term
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Definition
| Statistical Process Control |
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Term
| Statistical Process Control (SPC) |
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Definition
| A methodology for monitoring a process to identify special causes of variation and signal the need to take corrective action when appropriate |
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Term
| Histograms vs. Control Charts |
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Definition
Histograms do not take into account changes over time.
Control charts can tell us when a process changes |
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Term
| Steps to Developing Control Charts |
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Definition
Prepare
Collect Data
Determine trial control limits
Analyze and interpret results
Use as a problem-solving tool
Compute process capability |
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Term
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Definition
| the process of drilling down to a more specific problem statement |
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Term
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Definition
| the first step in any data collection effort is to develop this for all performance measures. |
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Term
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Definition
| the answers/problems that require identifying the key variables that are most likely to create errors and excessive variation |
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Term
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Definition
| a deviation between what should be happening and what actually is happening that is important enough to make someone think the deviation ought to be corrected |
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Term
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Definition
| a line graph in which data are plotted over time. vertical axis= a measurement; horizontal axis= the time scale |
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Term
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Definition
| simply a run chart with two control limits (upper and lower control limits) |
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Term
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Definition
| are chosen statistically to provide high probability that points fall between limits if the process is in control. make it easier to interpret patterns in a run chart and draw conclusions about its state of control. |
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Term
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Definition
| special types of data collection forms in which results maybe interpreted without additional processing. simple tools for data collection, usually a form. |
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Term
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Definition
| use simple columnar and tubular forms to record data |
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Term
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Definition
| a basic statistical tool that graphically shows the frequency or number of observations of a particular value or within a specified group. provides clues of a parent population from which a sample is taken, and shows patterns |
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Term
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Definition
| a simple graphical method for presenting a chain of causes and effects and for sorting out causes and organizing relationships between variables. |
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Term
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Definition
| are the graphical component of regression analysis. they often point to important relationships between variables |
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Term
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Definition
| focus on the elimination of waste in all forms (including rework defects, unnecessary processing, unnecessary movement of material, waiting time, excess inventory, and over production) |
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Term
| T/F Lean principles can be applied to non-manufacturing environments like banks and hospitals. |
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Definition
| true. called Lean enterprise |
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Term
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Definition
| using best practices of both Lean production and Six Sigma approaches. |
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Term
| differences in lean production and Six Sigma |
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Definition
1. lean production addresses visible problems in the process, whereas Six Sigma is focused on less visible problems like variation in performance.
2. Lean is focused on efficiency by reducing waste and improving process flow, whereas Six Sigma is on effectiveness by reducing errors and defects.
3. Lean tools are intuitive and anyone can do them, whereas Six Sigma tools require advanced training and expertise of Black Belt or Master Black Belt specialists. |
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Term
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Definition
| Six Sigma within the service sector. |
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Term
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Definition
| define opportunities, measure customer needs, explore design concepts, develop detailed design, implement detailed design |
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Term
| one of the most significant barriers to efficient product development is poor __ ___. |
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Definition
| intraorganizational cooperation |
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Term
| concurrent engineering (CE), aka simultaneous engineering |
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Definition
| requires multi funictional teams that develop the concept and decide what design methods are appropriate. The teams then analyze product functions and focus on the customer. |
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Term
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Definition
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Term
| 4 principles of Design for Six Sigma (DFSS) |
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Definition
1. concept development
2. design development
3. design optimization
4. design verification |
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Term
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Definition
| define, measure, analyze, design, and verify |
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Term
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Definition
| the process of applying scientific, aengineering and business knowledge to produce a basic functional design the meets both customer needs and manufacturing requirements |
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Term
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Definition
| a focused process for discovering customer requirements and using them to collect superior product or service concepts that meet those requirements |
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Term
| quality function deployment (QFD) |
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Definition
| a planning process, to guide design, manufacturing and marketing of goods by integrating the voice of the customer. Japanese approach |
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Term
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Definition
is a process
in which all major functions involved with bringing a product to market are continuously involved with product development from conception through sales. |
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Term
| Developing a basic functional design involves |
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Definition
| translating customer requirements into measurable technical requirements and, subsequently, into detailed design specifications. |
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Term
| Quality Function Deployment benefits companies through |
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Definition
| improved communication and teamwork between all constituencies in the value chain, such as between marketing and design, between design and manufacturing, and between purchasing and suppliers. |
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Term
| Product design can significantly affect the cost of manufacturing like: |
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Definition
| (direct and indirect labor, materials, and overhead), redesign, warranty, and field repair; the efficiency by which the product can be manufactured, and the quality of the output. |
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Term
| Design for Manufacturabilty - DFM |
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Definition
| the process of designing a product for efficient production at the highest level of quality. |
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Term
| Design for Manufacturability (DFM)is intended to |
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Definition
prevent product designs that simplify assembly operations but require more complex and expensive components, designs that simplify component manufacture while complicating the assembly process, and designs that are simple and inexpensive to
produce but difficult or expensive
to service or support. |
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Term
| Design-for-Environment (DFE) |
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Definition
| the explicit consideration of environmental concerns during the design of products and processes, and includes such practices as designing for recyclability and disassembly. |
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Term
| Design for Excellence (DFX) |
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Definition
| an emerging concept that includes many design-related initiatives such as concurrent engineering, design for manufacturability, design for assembly, design for environment, and other “design for” approaches |
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Term
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Definition
| refers to the ideal dimension or the target value that manufacturing seeks to meet |
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Term
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Definition
| is the permissible variation, recognizing the difficulty of meeting a target consistently. |
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Term
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Definition
Narrow tolerances
Wide tolerances |
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Term
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Definition
| tend to raise manufacturing costs but they also increase the interchangeability of parts within the plant and in the field, product performance, durability, and appearance. |
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Term
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Definition
| increase material utilization, machine throughput, and labor productivity, but have a negative impact on product characteristics |
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Term
| Tolerances are necessary because |
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Definition
| not all parts can be produced exactly to nominal specifications because of natural variations (common causes) in production processes due to the “5 Ms”: men and women, materials, machines, methods, and measurement. |
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Term
| Tools for Design Optimization |
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Definition
Taguchi loss function
Design failure mode and effects analysis (DFMEA)
Reliability |
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Term
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Definition
| suggests that no strict cut-off divides good quality from poor quality |
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Term
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Definition
| ability of a product to perform as expected over time |
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Term
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Definition
| A measure of variation that is independent of specification limits, showing the average loss over the distribution of output |
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Term
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Definition
| the difference between the true value and the observed average of a measurement. |
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Term
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Definition
| the closeness of repeated measurements to each other. |
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Term
| repeatability, or equipment variation |
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Definition
| variation in multiple measurements by an individual using the same instrument. |
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Term
| reproducibility, operator variation |
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Definition
| variation in the same measuring instrument used by different individuals |
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Term
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Definition
| is the process of verifying the capability and performance of an item of measuring and test equipment compared to traceable measurement standards |
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Term
| Design failure mode and effects analysis (DFMEA) |
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Definition
| identification of all the ways in which a failure can occur |
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Term
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Definition
Functional failure
Reliability failure |
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Term
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Definition
| failure that occurs at the start of product life due to manufacturing or material detects |
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Term
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Definition
| failure after some period of use |
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Term
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Definition
| is necessary to ensure that designs will meet customer requirements and can be produced to specifications. |
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Term
| Whenever variation is observed in measurements, some portion is due to measurement system error. Some errors are systematic (called bias); others are random. The size of the errors relative to the measurement value can significantly affect ____. |
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Definition
| the quality of the data and resulting decisions. |
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Term
| NIST – National Institute of Standards and Technology |
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Definition
| assure that measurements made by different people in different places yield the same results. |
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Term
| MOST IMPORTANT functions of metrology is calibration : |
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Definition
| the comparison of a measurement device or system having a known relationship to national standards against another device or system whose relationship to national standards is unknown. |
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Term
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Definition
is the range over which the natural variation of a process occurs as determined by the system of common causes, that is, what the process can achieve under
stable conditions. |
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Term
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Definition
| how a process performs under ideal conditions |
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Term
| Process characterization study |
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Definition
| how a process performs under actual operating conditions |
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Term
| Component variability study |
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Definition
| relative contribution of different sources of variation (e.g., process factors, measurement system) |
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Term
Many practitioners suggest a “safe”
lower limit Cp of 1.5 (Standard Deviations). A value above
this level will ___. |
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Definition
| practically guarantee that all units produced by a controlled process will be within specifications. |
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Term
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Definition
|
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Term
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Definition
is a performance characteristic that is either present or absent in the product or service under consideration (e.g., in or out of tolerance, error/defect present or absent).
Expressed as proportions or rates |
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Term
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Definition
| continuous (e.g., length, weight, and time) |
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Term
| Control Charts for Variables Data |
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Definition
x-bar and R-charts
x-bar and s-charts
Charts for individuals (x-charts) |
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Term
| Control charts indicate when |
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Definition
| to take action, and more importantly, when to leave a process alone. |
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Term
| Control Chart Design Issues |
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Definition
Basis for sampling
Sample size
Frequency of sampling
Location of control limits |
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Term
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Definition
At the start of a process, five consecutive parts must fall within the green zone. If not, the production setup must be reevaluated before the full production run can be started.
Once regular operations commence, two parts are sampled. |
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Term
| Pre-control is not an adequate substitute for control charts and should only be used when ____. |
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Definition
| process capability is no greater than 88 percent of the tolerance, or equivalently, when Cp is at least 1.14. If the process mean tends to drift, then Cp should be higher. |
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