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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. How does Juran define quality?
To monitor a process when measurement by variables is used.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Fitness for use.

2. What is poka yoke?
To monitor a process when measurement by variables is used.
Workers - machines - materials.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Mistake-proofing.

3. What is a histogram?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Brand image.
They move closer to the center line.
The gap between specifications and how service is performed.

4. Who first studied randomness in industrial processes
Walter A. Shewhart
Prevention - appraisal - internal failure - external failure.
A tool that shows where there is waste in a process.
Failure Modes and Effects Analysis

5. Your production process meets customer specifications. Is your process in control?
10 for Hazardous without warning 1 for none
Not necessarily.
Lower skill requirements - faster - less chance for error.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

6. 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?
Variable.
False - because each machine will have different natural tolerances.
Mean time to failure.
The primary operating characteristics of a product.

7. Test for constant variance
Lower skill requirements - faster - less chance for 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.
The manager in charge of a process being improved in a Six Sigma project.
They move closer to the center line.

8. What do you do when a process is out of control?
Look for the assignable cause of non-random variation.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
=sqrt(Σ(x-x-bar)^2)/(n-1))
The ratio of outputs to inputs; 1-scrap.

9. In a regression - what does R-square tell you?
The target number of standard deviations from the mean for specifications.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Someone who is consistently against virtually everything.

10. What happens to control limits on an SPC chart when sample size is increased?
Producer risk.
Sampling for SPC is done real time.
Controlling quality at the source.
They move closer to the center line.

11. Simple Regression Analysis (one factor regression model)
= 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
They move closer to the center line.
Studying firms with the best performance in a particular area.
Is the way in which the failure is manifested.

12. Which quality guru developed the concept of loss to society?
Technical quality is the "what" of the service; functional quality is the "how."
A scatterplot.
Taguchi
Define - measure - analyze - improve - control.

13. What does SIPOC stand for?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Supplier - input - process - output - customer.
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

14. What is a Gage R&R?
Is what induces the failure
It's good -- but it's still out of control!
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).
Initiated before or at design concept finalization

15. What type of risk is associated with Type II Error?
A tool that shows the physical flows through a space.
Central Limit Theorem
Consumer risk.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

16. In a Z table - what is Z?
The number of standard deviations some value is from the mean.
95%
Large enough to find two of the attribute - on average.
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

17. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Look for the assignable cause of non-random variation.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Conformance to specifications.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

18. What is process capability?
Mean time to failure.
The ability of a process to consistently meet customer specifications.
Sampling for SPC is done real time.
= 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

19. PFMEA
100%
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Before production starts
To monitor a process when measurement by variables is used.

20. In a regression - what does the p value of F tell you?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Lean is waste reduction - Six Sigma is variation reduction.
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).
The House of Quality.

21. Define performance quality.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Brand image.
The primary operating characteristics of a product.
Consumer risk.

22. What is Jidoka?
Controlling quality at the source.
= yij - y(bar)i --> value minus sum of that treatment (of row)
The manager in charge of a process being improved in a Six Sigma project.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

23. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
Different types of defects are listed (used for Pareto chart)
Define - measure - analyze - improve - control.
Waste.

24. ANOVA

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25. What is the formula for the standard deviation of a proportion?
Is the consequence of the failure.
Controlling quality at the source.
=sqrt((p*(1-p)/n)
Variable.

26. Pareto Analysis
Initiated before or at design concept finalization
Controlling quality at the source.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
10 for Hazardous without warning 1 for none

27. What does DMAIC stand for?
It's good -- but it's still out of control!
Define - measure - analyze - improve - control.
Define - measure - analyze - design - verify.
Sampling for SPC is done real time.

28. What is a dashboard?
To be a member of a Six Sigma project team.
A tool that shows performance along key dimensions all at once.
Sampling for SPC is done real time.
Hold all input variables constant except one. Observe the response as you vary the single input.

29. If you can only collect categorical data - what type of SPC charting can you do?
Is the consequence of the failure.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Brand image.
Attribute.

30. Define benchmarking.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
=sqrt((p*(1-p)/n)
Studying firms with the best performance in a particular area.
A diagram that shows the relationships between activities in a project network.

31. Define takt time.
The cycle time required to meet demand.
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
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The gap between specifications and how service is performed.

32. What is the Deming Prize?
Mean time to failure.
Organize ideas into meaningful categories by recognizing their underlying similarity
To mentor/coach (and sometimes train) black belts.
The Japanese national quality award.

33. What is Value Stream Mapping?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Consumer risk.
A tool that shows where there is waste in a process.
X-bar-bar

34. Histogram by Hand
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) 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
To manage the Six Sigma project.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

35. In the Service Quality Gap Model - what is Gap 4?
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
Shifts - Trends - Repeating patterns - Correlation with known events
Sampling for SPC is done real time.
The gap between what is promised and what is delivered.

36. Uses of regression
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Supplier - input - process - output - customer.
The gap between what customers expect and the service they receive.

37. What is the role of a master black belt?
To mentor/coach (and sometimes train) black belts.
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).
Lean is waste reduction - Six Sigma is variation reduction.
Concluding there has not been an effect/change when there has.

38. What are the four categories of costs in Juran's framework?
Can't tell without a Range chart.
Supplier - input - process - output - customer.
Prevention - appraisal - internal failure - external failure.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

39. What are the four perspectives of the Balanced Scorecard?
Financial - customer - internal process - innovation and learning.
Organize ideas into meaningful categories by recognizing their underlying similarity
Speed - courtesy - competence - and ease of repair.
A brainstorming tool that shows the connections between ideas.

40. For what is an x-bar chart used?
To monitor a process when measurement by variables is used.
False - because each machine will have different natural tolerances.
10 for Hazardous without warning 1 for none
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).

41. If a Cp shows that a process is not capable - should you calculate Cpk?
Supplier - input - process - output - customer.
No -- if it is not the same - it can only be worse!
Defects Per Million Opportunities
Walter A. Shewhart

42. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Variable.
Attribute
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.
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

43. Manual Test for Nomality
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Variable.
0.9^3 or 72.9%
An assertion or conjecture concerning one or more populations

44. What does the abbreviation UCL stand for?
100%
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 amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Upper control limit.

45. Does it ever make sense to accept a job when a process is incapable?
Defects Per Million Opportunities
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 specifications and how service is performed.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

46. What quality tool formally incorporates the voice of the customer?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
No -- only if the process is also capable.
99.73%
QFD

47. What is an affinity diagram?
A brainstorming tool that shows the connections between ideas.
Sort - Set in Order - Shine - Standardize - Sustain
=sqrt((p*(1-p)/n)
QFD

48. Define features.
Not necessarily.
Is the consequence of the failure.
=sqrt((p*(1-p)/n)
The secondary characteristics of a product; "bells and whistles."

49. Disadvantages of DOE

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50. For what is a p-chart used?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
The US national quality award.
Outside.
To monitor a process when measurement by attribute is used.