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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. Creating a Run Chart
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Mean time to replacement.
Failure Modes and Effects Analysis
Variable.

2. Non-random patterns (Run Charts)
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
Fishbone - cause-and-effect diagram.
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:

3. Residual(eij)
= yij - y(bar)i --> value minus sum of that treatment (of row)
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
100%
Observed variation in response is caused by the input

4. 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?
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
Initiated before or at design concept finalization
False - because each machine will have different natural tolerances.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

5. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Lower skill requirements - faster - less chance for error.
The gap between what customers expect and the service they receive.
Initiated before or at design concept finalization
0.9^3 or 72.9%

6. What is process capability?
Attribute.
Define - measure - analyze - improve - control.
The ability of a process to consistently meet customer specifications.
What the value of the dependent variable is when the independent variable is zero.

7. What do you do when a process is out of control?
p-bar - the long-run percent defective.
Consumer risk.
Lean is waste reduction - Six Sigma is variation reduction.
Look for the assignable cause of non-random variation.

8. Simple Regression Analysis (one factor regression model)
Financial - customer - internal process - innovation and learning.
Producer risk.
The target number of standard deviations from the mean for specifications.
= 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

9. Design of Experiments (DOE) approach
Taguchi
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Can't tell without a Range chart.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

10. If a Cp shows that a process is not capable - should you calculate Cpk?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Causes that lead to a particular effect.
No -- if it is not the same - it can only be worse!
It's good -- but it's still out of control!

11. What are the four perspectives of the Balanced Scorecard?
Assigns scores to weighted criteria for each project under consideration.
The ratio of outputs to inputs; 1-scrap.
Financial - customer - internal process - innovation and learning.
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:

12. In Juran's Cost of Quality model - which categories of costs balance which other categories?
False - because each machine will have different natural tolerances.
Lean is waste reduction - Six Sigma is variation reduction.
Prevention and appraisal costs are balanced against internal and external failure.
Represents the behavior of a process

13. Residual
To monitor a process when measurement by attribute is used.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Different types of defects are listed (used for Pareto chart)
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

14. For what is an x-bar chart used?
To monitor a process when measurement by variables is used.
Mean time to failure.
Shows the temporal flow of activities in a project network.
The gap between what is promised and what is delivered.

15. List two components of prevention cost.
False - because each machine will have different natural tolerances.
They move closer to the center line.
Financial - customer - internal process - innovation and learning.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

16. What is muda
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.
Walter A. Shewhart
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

17. In the Service Quality Gap Model - what is Gap 5?
0.9^3 or 72.9%
= yij - y(bar)i --> value minus sum of that treatment (of row)
Fractional factorial designs (orthogonal arrays)
The gap between what customers expect and the service they receive.

18. List Garvin's eight dimensions of product quality.
99.73%
3.4 (assuming 1.5 sigma shift in the mean)
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.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

19. What is a histogram?
Is the consequence of the failure.
Rapid improvement process.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Inventory = throughput x flow time.

20. Define product reliability.
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
Mean time to failure.
Outside.
Prevention and appraisal costs are balanced against internal and external failure.

21. For what is a p-chart used?
F_alpha - df(tr) - df (error)
A brainstorming tool that shows the connections between ideas.
To monitor a process when measurement by attribute is used.
A scatterplot.

22. Failure effect
Is the consequence of the failure.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Look for the assignable cause of non-random variation.
Controlling quality at the source.

23. One factor at a time (OFAT)
The gap between what management thinks customers want and what customers really want.
Hold all input variables constant except one. Observe the response as you vary the single input.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
10 for Hazardous without warning 1 for none

24. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Defects Per Million Opportunities
Fewer good units to sell - increased variable cost/unit.
Sampling for SPC is done real time.
Taguchi

25. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Causes that lead to a particular effect.
Outside.
The gap between specifications and how service is performed.
5%

26. In a regression - what does the p value of F tell you?
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).
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).
Because the mean and standard deviation are independent of each other.

27. Define durability.
Mean time to replacement.
A brainstorming tool that shows the connections between ideas.
No -- the variation also has to be random and "expected."
To do a capability study for a non-centered process.

28. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Taguchi
Large enough to find two of the attribute - on average.
To monitor a process when measurement by attribute is used.
Lean (or JIT).

29. What does the abbreviation UCL stand for?
Variable.
To obtain a certain desirable outcome from the process
The cycle time required to meet demand.
Upper control limit.

30. Cause and Effect Diagrams
Different types of defects are listed (used for Pareto chart)
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
Method developed by Ishikawa to graphically display the causes of any given problem
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

31. In a regression - what does the standard error of the estimate tell you?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Shifts - Trends - Repeating patterns - Correlation with known events
Concluding there has been an effect/change when there has not.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

32. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
10 for Hazardous without warning 1 for none
Kaoru Ishikawa.
Fishbone - cause-and-effect diagram.
Variable.

33. Who developed the fishbone diagram?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
A tool that shows the physical flows through a space.
Defects Per Million Opportunities
Kaoru Ishikawa.

34. Pareto Analysis
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Variable.
Sampling for SPC is done real time.
The cycle time required to meet demand.

35. What quality guru emphasizes management as a system?
To do a capability study for a non-centered process.
Deming.
They move closer to the center line.
Used to create frequency distribution tally sheets

36. What does the abbreviation LCL stand for?
The secondary characteristics of a product; "bells and whistles."
Observed variation in response is caused by the input
Lower control limit.
Conformance to specifications.

37. Affinity Diagrams
Organize ideas into meaningful categories by recognizing their underlying similarity
To be a member of a Six Sigma project team.
Method developed by Ishikawa to graphically display the causes of any given problem
100%

38. What is a CAVE man?
Different types of defects are listed (used for Pareto chart)
99.73%
Someone who is consistently against virtually everything.
Concluding there has been an effect/change when there has not.

39. What type of risk is associated with Type II Error?
Consumer risk.
Because the mean and standard deviation are independent of each other.
Shows the temporal flow of activities in a project network.
A brainstorming tool that shows the connections between ideas.

40. Disadvantages of DOE

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41. What is Type II Error?
Concluding there has not been an effect/change when there has.
X-bar-bar
Lower control limit.
10 for Hazardous without warning 1 for none

42. In the Service Quality Gap Model - what is Gap 1?
Mean time to failure.
Hold all input variables constant except one. Observe the response as you vary the single input.
The gap between what management thinks customers want and what customers really want.
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

43. What is DMADV?
Method developed by Ishikawa to graphically display the causes of any given problem
Controlling quality at the source.
No -- if it is not the same - it can only be worse!
Define - measure - analyze - design - verify.

44. Define benchmarking.
Studying firms with the best performance in a particular area.
Attribute.
Shifts - Trends - Repeating patterns - Correlation with known events
Stratify a particular defect type according to logical criteria

45. What type of risk is associated with Type 1 Error?
Conformance to specifications.
A tool that shows the physical flows through a space.
Producer 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).

46. Define features.
The secondary characteristics of a product; "bells and whistles."
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Mean time to replacement.

47. Define performance quality.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
The primary operating characteristics of a product.
Waste.
Shifts - Trends - Repeating patterns - Correlation with known events

48. 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
Producer risk.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

49. One factor at a time (OFAT)
Prevention - appraisal - internal failure - external failure.
Waste.
Observed variation in response is caused by the input
Supplier - input - process - output - customer.

50. FMEA
No -- if it is not the same - it can only be worse!
It looks to minimize the probability of a failure - or to minimize its effects
Upper control limit.
The ratio of outputs to inputs; 1-scrap.