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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 is Value Stream Mapping?
Pleasing to the senses.
5%
A tool that shows where there is waste in a process.
The manager in charge of a process being improved in a Six Sigma project.

2. What is muda
Different types of defects are listed (used for Pareto chart)
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Waste.
Inventory = throughput x flow time.

3. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
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
Conformance to specifications.
Represents the behavior of a process
Can't tell without a Range chart.

4. DFMEA
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Sampling for SPC is done real time.
Initiated before or at design concept finalization
Lean (or JIT).

5. What is poka yoke?
Outside.
Mistake-proofing.
It's good -- but it's still out of control!
To be a member of a Six Sigma project team.

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

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7. TWO-DIMENTIONAL SCATTER PLOT
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Central Limit Theorem
Fractional factorial designs (orthogonal arrays)
Defects Per Million Opportunities

8. For what is an x-bar chart used?
Mistake-proofing.
The cycle time required to meet demand.
To monitor a process when measurement by variables is used.
99.73%

9. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
Sampling for SPC is done real time.
Sort - Set in Order - Shine - Standardize - Sustain
Consumer risk.

10. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Blame.
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
Is the way in which the failure is manifested.
5%

11. What is FMEA?
Failure Modes and Effects Analysis
Outside.
50%
Critical to quality.

12. Which type of SPC measurement is more precise - variable or attribute?
The number of standard deviations some value is from the mean.
To monitor a process when measurement by variables is used.
The US national quality award.
Variable.

13. In the Service Quality Gap Model - what is Gap 5?
The gap between what management thinks customers want and the process specifications.
The gap between what customers expect and the service they receive.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

14. If you have calculated a Cpk - should you also calculate a Cp?
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
Causes that lead to a particular effect.
Central Limit Theorem
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

15. What does DMAIC stand for?
p-bar - the long-run percent defective.
Define - measure - analyze - improve - control.
Is what induces the failure
A tool that shows the physical flows through a space.

16. Uses of regression
99.73%
0.9^3 or 72.9%
Represents the behavior of a process
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

17. Risk Priority Number RPN
Upper control limit.
The gap between what management thinks customers want and what customers really want.
=sqrt(Σ(x-x-bar)^2)/(n-1))
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

18. Define benchmarking.
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
Look for the assignable cause of non-random variation.
To do a capability study for a non-centered process.
Studying firms with the best performance in a particular area.

19. In the Service Quality Gap Model - what is Gap 1?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
A diagram that shows the relationships between activities in a project network.
consists of plotting the residuals vs. the order of each experiment - If - as in the case of the constant variance a random horizontal band is obtained - the ______________ of the residuals is not rejected. (should be random above a below the line i
The gap between what management thinks customers want and what customers really want.

20. When yields decrease - what are the two effects on contribution?
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.
99.73%
Fewer good units to sell - increased variable cost/unit.
Before production starts

21. Affinity Diagrams
Fitness for use.
Organize ideas into meaningful categories by recognizing their underlying similarity
The US national quality award.
Initiated before or at design concept finalization

22. Uses of regression - Control
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:
To obtain a certain desirable outcome from the process
Inventory = throughput x flow time.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

23. Complete this quality phrase: 'Fix the process - not the _____.'
Variable.
Blame.
95%
A time series plot.

24. Process occurance ranking
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
To do a capability study for a non-centered process.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

25. List two components of external failure.
Pleasing to the senses.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
To monitor a process when measurement by attribute is used.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

26. FMEA
It looks to minimize the probability of a failure - or to minimize its effects
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Fitness for use.
The ability of a process to consistently meet customer specifications.

27. What are the three main categories of assignable cause?
Concluding there has not been an effect/change when there has.
Look for the assignable cause of non-random variation.
Workers - machines - materials.
5%

28. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Shifts - Trends - Repeating patterns - Correlation with known events
It looks to minimize the probability of a failure - or to minimize its effects
F_alpha - df(tr) - df (error)
Variable.

29. Taguchi's experimental designs are of this type.
Mean time to replacement.
Different types of defects are listed (used for Pareto chart)
Prevention - appraisal - internal failure - external failure.
Fractional factorial designs (orthogonal arrays)

30. Affinity Diagrams
Shows the temporal flow of activities in a project network.
Controlling quality at the source.
10 for Hazardous without warning 1 for none
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

31. How are LQL and AQL determined in an acceptance sampling plan?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Used to create frequency distribution tally sheets
Lean is waste reduction - Six Sigma is variation reduction.
Through producer/consumer negotiation.

32. Define durability.
p-bar - the long-run percent defective.
Used to create frequency distribution tally sheets
Mean time to replacement.
Fewer good units to sell - increased variable cost/unit.

33. What is the difference between Lean and Six Sigma?
= 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
A tool that shows the physical flows through a space.
What the value of the dependent variable is when the independent variable is zero.
Lean is waste reduction - Six Sigma is variation reduction.

34. What happens to control limits on an SPC chart when sample size is increased?
Lean (or JIT).
They move closer to the center line.
Large enough to find two of the attribute - on average.
F_alpha - df(tr) - df (error)

35. What type of risk is associated with Type 1 Error?
Producer risk.
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).
To mentor/coach (and sometimes train) black belts.
Variable.

36. What does Crosby say about benchmarking?
To obtain a certain desirable outcome from the process
The cycle time required to meet demand.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Defects Per Million Opportunities

37. What quality guru emphasizes management as a system?
The gap between what customers expect and the service they receive.
Producer risk.
Assigns scores to weighted criteria for each project under consideration.
Deming.

38. For what is a p-chart used?
To monitor a process when measurement by attribute is used.
Hold all input variables constant except one. Observe the response as you vary the single input.
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).
A tool that shows performance along key dimensions all at once.

39. FMEA
No -- only if the process is also capable.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Inventory = throughput x flow time.
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

40. What is an affinity diagram?
The target number of standard deviations from the mean for specifications.
The gap between what management thinks customers want and the process specifications.
A brainstorming tool that shows the connections between ideas.
The number of standard deviations some value is from the mean.

41. Define serviceability.
Large enough to find two of the attribute - on average.
Speed - courtesy - competence - and ease of repair.
The degree to which a product meets pre-established standards.
Is what induces the failure

42. What is a dashboard?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
A tool that shows performance along key dimensions all at once.
Someone who is consistently against virtually everything.
To mentor/coach (and sometimes train) black belts.

43. 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?
Lower control limit.
False - because each machine will have different natural tolerances.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
= 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

44. What is process capability?
p-bar - the long-run percent defective.
Represents the behavior of a process
Mean time to failure.
The ability of a process to consistently meet customer specifications.

45. Define perceived quality (Garvin's framework).
Kaoru Ishikawa.
Brand image.
Define - measure - analyze - design - verify.
Lower skill requirements - faster - less chance for error.

46. Failure effect
A time series plot.
A scatterplot.
Is the consequence of the failure.
To monitor a process when measurement by attribute is used.

47. Detection Criteria Ranking
10 if Almost impossible to detect
F_alpha - df(tr) - df (error)
The ability of a process to consistently meet customer specifications.
The gap between specifications and how service is performed.

48. In a regression - what does R-square tell you?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Waste.
10 if Almost impossible to detect
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

49. What is a Gage R&R?
Hold all input variables constant except one. Observe the response as you vary the single input.
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).
Sampling for SPC is done real time.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

50. DOE
What the value of the dependent variable is when the independent variable is zero.
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 ability of a process to consistently meet customer specifications.
Inventory = throughput x flow time.