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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. Define durability.
Mean time to replacement.
Sampling for SPC is done real time.
It looks to minimize the probability of a failure - or to minimize its effects
Fishbone - cause-and-effect diagram.

2. To what does the Six in Six Sigma relate?
Speed - courtesy - competence - and ease of repair.
Can't tell without a Range chart.
The target number of standard deviations from the mean for specifications.
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

3. Affinity Diagrams
Fitness for use.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Fewer good units to sell - increased variable cost/unit.
They move closer to the center line.

4. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
The US national quality award.
Failure Modes and Effects Analysis

5. What type of risk is associated with Type II Error?
Consumer risk.
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).
Waste.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

6. What is DPMO?
A scatterplot.
Different types of defects are listed (used for Pareto chart)
Through producer/consumer negotiation.
Defects Per Million Opportunities

7. Name the structure associated with Quality Function Deployment.
Represents the behavior of a process
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Attribute
The House of Quality.

8. What is written on the "spines" of a fishbone diagram?
10 if Almost impossible to detect
Causes that lead to a particular effect.
Is what induces the failure
Defects Per Million Opportunities

9. Creating a Run Chart
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
They move closer to the center line.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Workers - machines - materials.

10. Defect location check sheets
Lean is waste reduction - Six Sigma is variation reduction.
Actual drawings - layouts - maps - etc which show where a defect occurs
X-bar-bar
Defects Per Million Opportunities

11. Residual
Producer risk.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Shifts - Trends - Repeating patterns - Correlation with known events
To do a capability study for a non-centered process.

12. 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
Attribute
Can't tell without a Range chart.
X-bar-bar

13. Pareto Analysis
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The cycle time required to meet demand.
Can't tell without a Range chart.
Central Limit Theorem

14. Define product reliability.
10 if Almost impossible to detect
Mean time to failure.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
QFD

15. One factor at a time (OFAT)
Defects Per Million Opportunities
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Hold all input variables constant except one. Observe the response as you vary the single input.
A brainstorming tool that shows the connections between ideas.

16. Daniel Test
Can't tell without a Range chart.
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:
They move closer to the center line.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

17. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
3.4 (assuming 1.5 sigma shift in the mean)
Lean (or JIT).
No -- only if the process is also capable.
X-bar-bar

18. What is Jidoka?
Conformance to specifications.
Controlling quality at the source.
Attribute.
The gap between what is promised and what is delivered.

19. 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?
5%
A random variable that summarizes the information from the sample(s).
False - because each machine will have different natural tolerances.
Sampling for SPC is done real time.

20. What is the Deming Prize?
Actual drawings - layouts - maps - etc which show where a defect occurs
Someone who is consistently against virtually everything.
The Japanese national quality award.
To mentor/coach (and sometimes train) black belts.

21. What is the role of a master black belt?
Speed - courtesy - competence - and ease of repair.
Is the way in which the failure is manifested.
To mentor/coach (and sometimes train) black belts.
3.4 (assuming 1.5 sigma shift in the mean)

22. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Waste.
Taguchi

23. List two components of external failure.
The gap between what management thinks customers want and the process specifications.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
False - because each machine will have different natural tolerances.
Concluding there has not been an effect/change when there has.

24. What is a Pareto chart?
A descending order-sorted bar chart with a cumulative percentage line.
The gap between what is promised and what is delivered.
Financial - customer - internal process - innovation and learning.
Producer risk.

25. What is the role of a green belt?
The manager in charge of a process being improved in a Six Sigma project.
To be a member of a Six Sigma project team.
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
Variable.

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

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27. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Linearity - normality - homoscedasticity - independence.
p-bar - the long-run percent defective.
68%
Technical quality is the "what" of the service; functional quality is the "how."

28. In the Service Quality Gap Model - what is Gap 4?
Is the way in which the failure is manifested.
Shifts - Trends - Repeating patterns - Correlation with known events
Through producer/consumer negotiation.
The gap between what is promised and what is delivered.

29. What is CTQ?
A random variable that summarizes the information from the sample(s).
The manager in charge of a process being improved in a Six Sigma project.
Critical to quality.
Producer risk.

30. Explain the difference between technical and functional service quality.
68%
Technical quality is the "what" of the service; functional quality is the "how."
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The gap between what management thinks customers want and the process specifications.

31. How are LQL and AQL determined in an acceptance sampling plan?
Linearity - normality - homoscedasticity - independence.
Through producer/consumer negotiation.
To manage the Six Sigma project.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

32. Define benchmarking.
Can't tell without a Range chart.
A random variable that summarizes the information from the sample(s).
Studying firms with the best performance in a particular area.
Linearity - normality - homoscedasticity - independence.

33. Defect check sheets
Different types of defects are listed (used for Pareto chart)
No -- the variation also has to be random and "expected."
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Supplier - input - process - output - customer.

34. FMEA
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
Actual drawings - layouts - maps - etc which show where a defect occurs
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Fractional factorial designs (orthogonal arrays)

35. In the Service Quality Gap Model - what is Gap 1?
=sqrt(Σ(x-x-bar)^2)/(n-1))
Observed variation in response is caused by the input
The gap between what management thinks customers want and what customers really want.
A brainstorming tool that shows the connections between ideas.

36. Non-random patterns (Run Charts)
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
= yij - y(bar)i --> value minus sum of that treatment (of row)
The ability of a process to consistently meet customer specifications.
Shifts - Trends - Repeating patterns - Correlation with known events

37. If you can only collect categorical data - what type of SPC charting can you do?
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
Shifts - Trends - Repeating patterns - Correlation with known events
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Attribute.

38. What does a project prioritization matrix do?
The secondary characteristics of a product; "bells and whistles."
The ability of a process to consistently meet customer specifications.
10 if Almost impossible to detect
Assigns scores to weighted criteria for each project under consideration.

39. Process occurance ranking
Lower skill requirements - faster - less chance for error.
95%
Sampling for SPC is done real time.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

40. What graphical tool is used to show the relationship between two numerical variables?
A scatterplot.
Shows the temporal flow of activities in a project network.
Fractional factorial designs (orthogonal arrays)
Critical to quality.

41. If you have calculated a Cpk - should you also calculate a Cp?
Is the consequence of the failure.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

42. If a Cp shows that a process is not capable - should you calculate Cpk?
Causes that lead to a particular effect.
No -- if it is not the same - it can only be worse!
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Fitness for use.

43. What is the Baldrige Award?
95%
The US national quality award.
Inventory = throughput x flow time.
Defects Per Million Opportunities

44. Test for Independence
10 for Hazardous without warning 1 for none
Defects Per Million Opportunities
Lean (or JIT).
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

45. What is Little's Law?
Inventory = throughput x flow time.
The US national quality award.
Kaoru Ishikawa.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

46. List two components of internal failure.
Blame.
Scrap - rework - retest - downtime - yield losses - disposition costs.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Rapid improvement process.

47. PFMEA
Before production starts
Prevention - appraisal - internal failure - external failure.
Defects Per Million Opportunities
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

48. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Conformance to specifications.
Consumer 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).
The gap between what management thinks customers want and what customers really want.

49. Risk Priority Number RPN
Hold all input variables constant except one. Observe the response as you vary the single input.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Kaoru Ishikawa.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

50. Define perceived quality (Garvin's framework).
Brand image.
Studying firms with the best performance in a particular area.
No -- if it is not the same - it can only be worse!
The US national quality award.