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Six Sigma

Subjects : certifications, six-sigma, business-skills

Instructions:

Answer 50 questions in 15 minutes.
If you are not ready to take this test, you can study here.
Match each statement with the correct term.
Don't refresh. All questions and answers are randomly picked and ordered every time you load a test.

This is a study tool. The 3 wrong answers for each question are randomly chosen from answers to other questions. So, you might find at times the answers obvious, but you will see it re-enforces your understanding as you take the test each time.

1. Which quality guru developed the concept of loss to society?
Taguchi
Supplier - input - process - output - customer.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
They move closer to the center line.

2. There are two milling machines in the shop. Data has been collected on one to compute control limits for both. This is acceptable SPC practice - true or false and why?
False - because each machine will have different natural tolerances.
Concluding there has not been an effect/change when there has.
To do a capability study for a non-centered process.
Consumer risk.

3. If a three-stage process has 90% yields at each stage - what is the overall yield?
Initiated before or at design concept finalization
Failure Modes and Effects Analysis
0.9^3 or 72.9%
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

4. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Mistake-proofing.
To manage the Six Sigma project.
Supplier - input - process - output - customer.
Conformance to specifications.

5. In the Service Quality Gap Model - what is Gap 3?
X-bar-bar
Look for the assignable cause of non-random variation.
The gap between specifications and how service is performed.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

6. Uses of regression - Control
A tool that shows performance along key dimensions all at once.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
To obtain a certain desirable outcome from the process
It usually isn't possible to hold all other variables constant - There is no way to account for the effect of joint variation of independent variables - such as interaction - There is no way to account for experimental error - including measurement v

7. Taguchi's experimental designs are of this type.
The gap between what management thinks customers want and what customers really want.
An assertion or conjecture concerning one or more populations
Define - measure - analyze - improve - control.
Fractional factorial designs (orthogonal arrays)

8. In a regression - what does the p value of F tell you?
A tool that shows the physical flows through a space.
Before production starts
Look for the assignable cause of non-random variation.
How likely it is to have an F statistic of that value if there really is no relationship between the dependent variable and the independent variable(s).

9. Creating a Run Chart
Someone who is consistently against virtually everything.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
No -- the variation also has to be random and "expected."
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

10. What quality tool formally incorporates the voice of the customer?
QFD
1.Interactions can be detected and measured 2.Each value does the work of several values 3.Experimental error is quantified and used to determine the confidence the experimenter has in the conclusions
50%
Someone who is consistently against virtually everything.

11. What happens to control limits on an SPC chart when sample size is increased?
The US national quality award.
Shifts - Trends - Repeating patterns - Correlation with known events
They move closer to the center line.
Stratify a particular defect type according to logical criteria

12. Why do you need two control charts for variables SPC?
Large enough to find two of the attribute - on average.
Organize ideas into meaningful categories by recognizing their underlying similarity
Different types of defects are listed (used for Pareto chart)
Because the mean and standard deviation are independent of each other.

13. Failure cause
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The gap between what is promised and what is delivered.
Is what induces the failure
Variable.

14. Uses of regression
The ability of a process to consistently meet customer specifications.
Define - measure - analyze - improve - control.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

15. Define serviceability.
Speed - courtesy - competence - and ease of repair.
Variable.
Is the consequence of the failure.
What the value of the dependent variable is when the independent variable is zero.

16. The data points on an SPC p-chart of defective percent plot below the mean. Is this good or bad?

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17. What are two other names for an Ishikawa diagram?
Because the mean and standard deviation are independent of each other.
Hold all input variables constant except one. Observe the response as you vary the single input.
Plot the residuals vs. the fitted values (mean of each group - y(hat) = y (bar)i ) - Assumption of ____________not rejected if the dispersion of every group is approximately the same.
Fishbone - cause-and-effect diagram.

18. What is process capability?
Fishbone - cause-and-effect diagram.
Prevention - appraisal - internal failure - external failure.
The ability of a process to consistently meet customer specifications.
Scrap - rework - retest - downtime - yield losses - disposition costs.

19. What are the four perspectives of the Balanced Scorecard?
Actual drawings - layouts - maps - etc which show where a defect occurs
To monitor a process when measurement by variables is used.
Financial - customer - internal process - innovation and learning.
Rapid improvement process.

20. Based on what principal can we use the normal distribution assumptions for SPC?
Consumer risk.
Central Limit Theorem
Critical to quality.
Fewer good units to sell - increased variable cost/unit.

21. Residual(eij)
95%
= yij - y(bar)i --> value minus sum of that treatment (of row)
The degree to which a product meets pre-established standards.
The primary operating characteristics of a product.

22. In the Service Quality Gap Model - what is Gap 4?
The gap between what is promised and what is delivered.
5%
Decomposing the total variation of data into: (a) the internal or "natural" or "within" groups variation - and (b) the "between" groups variation in such a way that when these two types of variation are compared - it's possible to determine if there
Because the mean and standard deviation are independent of each other.

23. What is the 5S model?
To manage the Six Sigma project.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

24. What is written on the "spines" of a fishbone diagram?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Prevention - appraisal - internal failure - external failure.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Causes that lead to a particular effect.

25. What is Type II Error?
Plot the residuals vs. the fitted values (mean of each group - y(hat) = y (bar)i ) - Assumption of ____________not rejected if the dispersion of every group is approximately the same.
Fitness for use.
Concluding there has not been an effect/change when there has.
Variable.

26. How are LQL and AQL determined in an acceptance sampling plan?
Waste.
Through producer/consumer negotiation.
The cycle time required to meet demand.
An assertion or conjecture concerning one or more populations

27. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Variable.
Prevention and appraisal costs are balanced against internal and external failure.
Linearity - normality - homoscedasticity - independence.
Method developed by Ishikawa to graphically display the causes of any given problem

28. What graphical tool is used to show the relationship between two numerical variables?
How likely it is to have an F statistic of that value if there really is no relationship between the dependent variable and the independent variable(s).
Pleasing to the senses.
A scatterplot.
68%

29. What does Crosby say about benchmarking?
Lean (or JIT).
50%
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

30. What do you do when a process is out of control?
Look for the assignable cause of non-random variation.
Conformance to specifications.
To manage the Six Sigma project.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

31. What is CTQ?
Because the mean and standard deviation are independent of each other.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The ratio of outputs to inputs; 1-scrap.
Critical to quality.

32. TWO-DIMENTIONAL SCATTER PLOT
Speed - courtesy - competence - and ease of repair.
Large enough to find two of the attribute - on average.
The manager in charge of a process being improved in a Six Sigma project.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

33. If you have calculated a Cpk - should you also calculate a Cp?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Scrap - rework - retest - downtime - yield losses - disposition costs.
What the value of the dependent variable is when the independent variable is zero.
It looks to minimize the probability of a failure - or to minimize its effects

34. DOE
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Before production starts
It usually isn't possible to hold all other variables constant - There is no way to account for the effect of joint variation of independent variables - such as interaction - There is no way to account for experimental error - including measurement v
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

35. What is a Gage R&R?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The House of Quality.
A tools that is used to measure the amount of variation in the measurement system arising from the measurement device (repeatability) and the people taking the measurement (reproducibility).

36. In the Service Quality Gap Model - what is Gap 1?
QFD
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The gap between what management thinks customers want and what customers really want.
To monitor a process when measurement by variables is used.

37. Affinity Diagrams
Shows the temporal flow of activities in a project network.
Organize ideas into meaningful categories by recognizing their underlying similarity
Central Limit Theorem
Failure Modes and Effects Analysis

38. What is a network diagram?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
A diagram that shows the relationships between activities in a project network.

39. What is the Deming Prize?
Define - measure - analyze - improve - control.
The Japanese national quality award.
Walter A. Shewhart
Fewer good units to sell - increased variable cost/unit.

40. What quality guru emphasizes management as a system?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Deming.
Prevention - appraisal - internal failure - external failure.
Failure Modes and Effects Analysis

41. For what is a p-chart used?
To do a capability study for a non-centered process.
To monitor a process when measurement by attribute is used.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Variable.

42. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Before production starts
Producer risk.

43. Residual
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Inventory = throughput x flow time.
Linearity - normality - homoscedasticity - independence.
False - because each machine will have different natural tolerances.

44. What does the abbreviation UCL stand for?
Studying firms with the best performance in a particular area.
Controlling quality at the source.
Upper control limit.
Another way to assess the significance of the analyzed factors is through a graphic procedure developed by C. Daniel when only one replicate (a single observation) was obtained:

45. With Six Sigma capability - how many defects per million opportunities would you see?
Failure Modes and Effects Analysis
Rapid improvement process.
3.4 (assuming 1.5 sigma shift in the mean)
Financial - customer - internal process - innovation and learning.

46. What are the Five Dimensions of Service Quality?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
A time series plot.
Variable.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

47. A process is operating "in control." Does this mean the customer's requirements are met?
No -- only if the process is also capable.
Workers - machines - materials.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Consumer risk.

48. Who first studied randomness in industrial processes
QFD
Walter A. Shewhart
A tool that shows where there is waste in a process.
Fishbone - cause-and-effect diagram.

49. What is a dashboard?
Organize ideas into meaningful categories by recognizing their underlying similarity
To be a member of a Six Sigma project team.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A tool that shows performance along key dimensions all at once.

50. What is a run chart?
False - because each machine will have different natural tolerances.
99.73%
A time series plot.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality