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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. PFMEA
Shows the temporal flow of activities in a project network.
Variable.
Define - measure - analyze - improve - control.
Before production starts

2. What is CTQ?
What the value of the dependent variable is when the independent variable is zero.
The number of standard deviations some value is from the mean.
Critical to quality.
X-bar-bar

3. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Represents the behavior of a process
Sampling for SPC is done real time.
5%
A descending order-sorted bar chart with a cumulative percentage line.

4. What is the center line of a p-chart?
The gap between what customers expect and the service they receive.
Shifts - Trends - Repeating patterns - Correlation with known events
p-bar - the long-run percent defective.
The Japanese national quality award.

5. What size should samples be for attribute SPC?
Rapid improvement process.
Shifts - Trends - Repeating patterns - Correlation with known events
Variable.
Large enough to find two of the attribute - on average.

6. What is a CAVE man?
Conformance to specifications.
5%
Deming.
Someone who is consistently against virtually everything.

7. You have been plotting sample means on an x-bar chart and all points indicate normal - expected variation. Is the process in control?

8. What is Little's Law?
99.73%
Fractional factorial designs (orthogonal arrays)
Inventory = throughput x flow time.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

9. Define benchmarking.
To mentor/coach (and sometimes train) black belts.
The secondary characteristics of a product; "bells and whistles."
Conformance to specifications.
Studying firms with the best performance in a particular area.

10. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
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
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The US national quality award.

11. Your production process meets customer specifications. Is your process in control?
F_alpha - df(tr) - df (error)
Rapid improvement process.
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).
Not necessarily.

12. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
68%
Variable.
Outside.
The primary operating characteristics of a product.

13. In the Service Quality Gap Model - what is Gap 5?
The gap between specifications and how service is performed.
To monitor a process when measurement by variables is used.
To monitor a process when measurement by attribute is used.
The gap between what customers expect and the service they receive.

14. What is FMEA?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Scrap - rework - retest - downtime - yield losses - disposition costs.
The target number of standard deviations from the mean for specifications.
Failure Modes and Effects Analysis

15. What is the role of a black belt?
Central Limit Theorem
Lower skill requirements - faster - less chance for error.
3.4 (assuming 1.5 sigma shift in the mean)
To manage the Six Sigma project.

16. 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?
Causes that lead to a particular effect.
Hold all input variables constant except one. Observe the response as you vary the single input.
Scrap - rework - retest - downtime - yield losses - disposition costs.
False - because each machine will have different natural tolerances.

17. Simple Regression Analysis (one factor regression model)
The primary operating characteristics of a product.
= 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
Central Limit Theorem
Actual drawings - layouts - maps - etc which show where a defect occurs

18. What are the 5 Ss?
To monitor a process when measurement by attribute is used.
Sort - Set in Order - Shine - Standardize - Sustain
Brand image.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

19. What quality tool formally incorporates the voice of the customer?
The primary operating characteristics of a product.
Lean (or JIT).
QFD
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

20. In the Service Quality Gap Model - what is Gap 4?
Shifts - Trends - Repeating patterns - Correlation with known events
The gap between what is promised and what is delivered.
Attribute.
The number of standard deviations some value is from the mean.

21. A process is operating "in control." Does this mean the customer's requirements are met?
Concluding there has not been an effect/change when there has.
No -- only if the process is also capable.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Represents the behavior of a process

22. What is a dashboard?
To do a capability study for a non-centered process.
A tool that shows performance along key dimensions all at once.
A diagram that shows the relationships between activities in a project network.
What the value of the dependent variable is when the independent variable is zero.

23. What do you do when a process is out of control?
Look for the assignable cause of non-random variation.
Taguchi
Supplier - input - process - output - customer.
Organize ideas into meaningful categories by recognizing their underlying similarity

24. Risk Priority Number RPN
A brainstorming tool that shows the connections between ideas.
Mean time to failure.
=sqrt((p*(1-p)/n)
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

25. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Prevention and appraisal costs are balanced against internal and external failure.
Organize ideas into meaningful categories by recognizing their underlying similarity
Blame.
The gap between what management thinks customers want and what customers really want.

26. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
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
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Waste.

27. Affinity Diagrams
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
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Causes that lead to a particular effect.
Organize ideas into meaningful categories by recognizing their underlying similarity

28. FMEA
It looks to minimize the probability of a failure - or to minimize its effects
100%
Before production starts
Used to create frequency distribution tally sheets

29. In the Service Quality Gap Model - what is Gap 3?
A brainstorming tool that shows the connections between ideas.
Central Limit Theorem
The gap between specifications and how service is performed.
Mistake-proofing.

30. Uses of regression
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Concluding there has not been an effect/change when there has.
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
Blame.

31. What type of risk is associated with Type 1 Error?
Upper control limit.
Controlling quality at the source.
The ability of a process to consistently meet customer specifications.
Producer risk.

32. Define serviceability.
Speed - courtesy - competence - and ease of repair.
Is the consequence of the failure.
68%
Scrap - rework - retest - downtime - yield losses - disposition costs.

33. Define conformance quality.
The gap between what customers expect and the service they receive.
The degree to which a product meets pre-established standards.
Method developed by Ishikawa to graphically display the causes of any given problem
Mean time to failure.

34. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
Different types of defects are listed (used for Pareto chart)
Fewer good units to sell - increased variable cost/unit.
Conformance to specifications.

35. Does it ever make sense to accept a job when a process is incapable?
The degree to which a product meets pre-established standards.
Lower control limit.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

36. What is written on the "spines" of a fishbone diagram?
Causes that lead to a particular effect.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Deming.
To do a capability study for a non-centered process.

37. Which quality guru developed the concept of loss to society?
Pleasing to the senses.
Concluding there has not been an effect/change when there has.
Taguchi
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

38. What is muda
It's good -- but it's still out of control!
Waste.
50%
Studying firms with the best performance in a particular area.

39. What is the difference between Lean and Six Sigma?
Brand image.
Lean is waste reduction - Six Sigma is variation reduction.
No -- only if the process is also capable.
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

40. When is Cpk used?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
A brainstorming tool that shows the connections between ideas.
Actual drawings - layouts - maps - etc which show where a defect occurs
To do a capability study for a non-centered process.

41. What is poka yoke?
To monitor a process when measurement by variables is used.
Mistake-proofing.
Speed - courtesy - competence - and ease of repair.
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.

42. List two components of internal failure.
Upper control limit.
Mean time to replacement.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Someone who is consistently against virtually everything.

43. With Six Sigma capability - how many defects per million opportunities would you see?
The cycle time required to meet demand.
3.4 (assuming 1.5 sigma shift in the mean)
To be a member of a Six Sigma project team.
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

44. Test for constant variance
The gap between what customers expect and the service they receive.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
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.
False - because each machine will have different natural tolerances.

45. In the Service Quality Gap Model - what is Gap 2?
Inventory = throughput x flow time.
Mistake-proofing.
The gap between what management thinks customers want and the process specifications.
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).

46. What are the four perspectives of the Balanced Scorecard?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Sort - Set in Order - Shine - Standardize - Sustain
The secondary characteristics of a product; "bells and whistles."
Financial - customer - internal process - innovation and learning.

47. What is the role of a master black belt?
To mentor/coach (and sometimes train) black belts.
Consumer risk.
Define - measure - analyze - improve - control.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

48. Define features.
Lean (or JIT).
= 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
The secondary characteristics of a product; "bells and whistles."
What the value of the dependent variable is when the independent variable is zero.

49. List two appraisal costs.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Mistake-proofing.
Causes that lead to a particular effect.
An assertion or conjecture concerning one or more populations

50. Define yield.
Define - measure - analyze - design - verify.
The US national quality award.
The ratio of outputs to inputs; 1-scrap.
Mistake-proofing.