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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. What quality guru emphasizes management as a system?
Shows the temporal flow of activities in a project network.
The gap between what management thinks customers want and the process specifications.
Deming.
No -- the variation also has to be random and "expected."

2. Failure Mode
Is the way in which the failure is manifested.
Financial - customer - internal process - innovation and learning.
Pleasing to the senses.
Lower skill requirements - faster - less chance for error.

3. Process check sheets
F_alpha - df(tr) - df (error)
Attribute.
Used to create frequency distribution tally sheets
Initiated before or at design concept finalization

4. Define aesthetic quality.
Before production starts
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).
Pleasing to the senses.
To mentor/coach (and sometimes train) black belts.

5. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
= yij - y(bar)i --> value minus sum of that treatment (of row)
Assigns scores to weighted criteria for each project under consideration.
Financial - customer - internal process - innovation and learning.
Conformance to specifications.

6. In the Service Quality Gap Model - what is Gap 3?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
To monitor a process when measurement by variables is used.
The gap between specifications and how service is performed.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

7. One factor at a time (OFAT)
A diagram that shows the relationships between activities in a project network.
68%
Hold all input variables constant except one. Observe the response as you vary the single input.
False - because each machine will have different natural tolerances.

8. Who first studied randomness in industrial processes
Critical to quality.
Is what induces the failure
Walter A. Shewhart
To manage the Six Sigma project.

9. Does it ever make sense to accept a job when a process is incapable?
Conformance to specifications.
Concluding there has been an effect/change when there has not.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Before production starts

10. What are the four perspectives of the Balanced Scorecard?
Financial - customer - internal process - innovation and learning.
A descending order-sorted bar chart with a cumulative percentage line.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
The gap between what customers expect and the service they receive.

11. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
Variable.
Central Limit Theorem
The ability of a process to consistently meet customer specifications.

12. In the Service Quality Gap Model - what is Gap 1?
The gap between what management thinks customers want and what customers really want.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

13. What is a run chart?
A time series plot.
Because the mean and standard deviation are independent of each other.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Controlling quality at the source.

14. What is the center line of a p-chart?
F_alpha - df(tr) - df (error)
The ratio of outputs to inputs; 1-scrap.
Sampling for SPC is done real time.
p-bar - the long-run percent defective.

15. What is an affinity diagram?
A brainstorming tool that shows the connections between ideas.
It's good -- but it's still out of control!
Workers - machines - materials.
A descending order-sorted bar chart with a cumulative percentage line.

16. Define serviceability.
68%
Speed - courtesy - competence - and ease of repair.
A scatterplot.
Kaoru Ishikawa.

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

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18. Disadvantages of DOE

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19. Failure effect
The secondary characteristics of a product; "bells and whistles."
95%
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Is the consequence of the failure.

20. What is a Pareto chart?
Mistake-proofing.
Fewer good units to sell - increased variable cost/unit.
A descending order-sorted bar chart with a cumulative percentage line.
Outside.

21. What does the abbreviation UCL stand for?
To manage the Six Sigma project.
Upper control limit.
= y = Beta(0) + Beta(1)X + epsilon y=dependent variable (response) x=independent variable (predictor of y) - epsilon=error component - Beta(not)=intersection. If data include zero - it represents the mean of the distribution of y when - x=0. It does
95%

22. What is the role of a master black belt?
To mentor/coach (and sometimes train) black belts.
Walter A. Shewhart
The Japanese national quality award.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

23. Affinity Diagrams
A random variable that summarizes the information from the sample(s).
Organize ideas into meaningful categories by recognizing their underlying similarity
To obtain a certain desirable outcome from the process
10 if Almost impossible to detect

24. Uses of regression
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Prevention and appraisal costs are balanced against internal and external failure.
The cycle time required to meet demand.
Defects Per Million Opportunities

25. What type of risk is associated with Type 1 Error?
Conformance to specifications.
Producer risk.
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.
The US national quality award.

26. Pareto Analysis
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Outside.
Is the consequence of the failure.
Failure Modes and Effects Analysis

27. How are LQL and AQL determined in an acceptance sampling plan?
Central Limit Theorem
The gap between what is promised and what is delivered.
Through producer/consumer negotiation.
Shifts - Trends - Repeating patterns - Correlation with known events

28. Name the structure associated with Quality Function Deployment.
Speed - courtesy - competence - and ease of repair.
Is the way in which the failure is manifested.
Fewer good units to sell - increased variable cost/unit.
The House of Quality.

29. Based on what principal can we use the normal distribution assumptions for SPC?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Central Limit Theorem
A time series plot.

30. DFMEA
Pleasing to the senses.
Initiated before or at design concept finalization
Look for the assignable cause of non-random variation.
Speed - courtesy - competence - and ease of repair.

31. Histogram by Hand
1) Identify the Range (Max Value - Min Value) 2) Determine # of bins 3) Determine the Width of each bin --> (Range / # Bins) 4) Put values in correct Bin
Method developed by Ishikawa to graphically display the causes of any given problem
Attribute
Studying firms with the best performance in a particular area.

32. The Test Statistic (TS)
Is the consequence of the failure.
A random variable that summarizes the information from the sample(s).
A scatterplot.
Failure Modes and Effects Analysis

33. If you have calculated a Cpk - should you also calculate a Cp?
Kaoru Ishikawa.
Conformance to specifications.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
0.9^3 or 72.9%

34. One factor at a time (OFAT)
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
A random variable that summarizes the information from the sample(s).
Observed variation in response is caused by the input

35. Residual
Lower control limit.
Scrap - rework - retest - downtime - yield losses - disposition costs.
50%
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

36. Statistical Hypothesis
Fewer good units to sell - increased variable cost/unit.
Fractional factorial designs (orthogonal arrays)
An assertion or conjecture concerning one or more populations
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

37. Define performance quality.
Studying firms with the best performance in a particular area.
The primary operating characteristics of a product.
Inventory = throughput x flow time.
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).

38. What is the center line of an X-bar chart?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Mean time to replacement.
Kaoru Ishikawa.
X-bar-bar

39. In a regression - what does R-square tell you?
Sort - Set in Order - Shine - Standardize - Sustain
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
A systemized group of activities designed to 1. recognize and evaluate the potential failure of product/process and its effects 2. Identify actions which could eliminate or reduce the chance of potential failure ocurring 3. document the process
Scrap - rework - retest - downtime - yield losses - disposition costs.

40. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
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
The US national quality award.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Variable.

41. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
99.73%
Pleasing to the senses.
A systemized group of activities designed to 1. recognize and evaluate the potential failure of product/process and its effects 2. Identify actions which could eliminate or reduce the chance of potential failure ocurring 3. document the process

42. In a Z table - what is Z?
Represents the behavior of a process
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
The number of standard deviations some value is from the mean.

43. ANOVA

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44. If a three-stage process has 90% yields at each stage - what is the overall yield?
The number of standard deviations some value is from the mean.
0.9^3 or 72.9%
The gap between what customers expect and the service they receive.
Concluding there has been an effect/change when there has not.

45. What is Type II Error?
The Japanese national quality award.
Concluding there has not been an effect/change when there has.
Different types of defects are listed (used for Pareto chart)
Blame.

46. If a Cp shows that a process is not capable - should you calculate Cpk?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Hold all input variables constant except one. Observe the response as you vary the single input.
No -- if it is not the same - it can only be worse!

47. Effect ranking (Severity of the Defect)
Walter A. Shewhart
10 for Hazardous without warning 1 for none
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
1) Identify the Range (Max Value - Min Value) 2) Determine # of bins 3) Determine the Width of each bin --> (Range / # Bins) 4) Put values in correct Bin

48. Who is a process owner?
Sampling for SPC is done real time.
F_alpha - df(tr) - df (error)
The manager in charge of a process being improved in a Six Sigma project.
Is the consequence of the failure.

49. Who developed the fishbone diagram?
Kaoru Ishikawa.
Fewer good units to sell - increased variable cost/unit.
X-bar-bar
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:

50. What is FMEA?
Shows the temporal flow of activities in a project network.
A tool that shows where there is waste in a process.
Failure Modes and Effects Analysis
Rapid improvement process.