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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. Failure Mode
No -- only if the process is also capable.
Is the way in which the failure is manifested.
The gap between what customers expect and the service they receive.
A tool that shows the physical flows through a space.

2. What is the difference between Lean and Six Sigma?
To obtain a certain desirable outcome from the process
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Lean is waste reduction - Six Sigma is variation reduction.
The degree to which a product meets pre-established standards.

3. List two components of external failure.
Pleasing to the senses.
No -- the variation also has to be random and "expected."
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

4. Define aesthetic quality.
What the value of the dependent variable is when the independent variable is zero.
A random variable that summarizes the information from the sample(s).
Pleasing to the senses.
Fractional factorial designs (orthogonal arrays)

5. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Variable.
Define - measure - analyze - improve - control.
The ratio of outputs to inputs; 1-scrap.
The US national quality award.

6. Define takt time.
The cycle time required to meet demand.
Attribute.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Prevention and appraisal costs are balanced against internal and external failure.

7. If a three-stage process has 90% yields at each stage - what is the overall yield?
0.9^3 or 72.9%
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Outside.
A time series plot.

8. Name the structure associated with Quality Function Deployment.
Define - measure - analyze - improve - control.
The House of Quality.
A time series plot.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

9. What is the formula for standard deviation?
The gap between what customers expect and the service they receive.
=sqrt(Σ(x-x-bar)^2)/(n-1))
The secondary characteristics of a product; "bells and whistles."
Concluding there has not been an effect/change when there has.

10. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Prevention and appraisal costs are balanced against internal and external failure.
The House of Quality.
5%

11. Risk Priority Number RPN
Outside.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
50%

12. 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?
To obtain a certain desirable outcome from the process
The target number of standard deviations from the mean for specifications.
10 for Hazardous without warning 1 for none
False - because each machine will have different natural tolerances.

13. What are the three main categories of assignable cause?
Failure Modes and Effects Analysis
Workers - machines - materials.
Taguchi
Reliability - Assurance - Responsiveness - Tangibles - Empathy

14. List two appraisal costs.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
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
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

15. What does SIPOC stand for?
= 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
Supplier - input - process - output - customer.
Blame.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

16. What is the center line of an X-bar chart?
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
X-bar-bar
Is what induces the failure
The Japanese national quality award.

17. Test for constant variance
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
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.
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

18. Why do you need two control charts for variables SPC?
Technical quality is the "what" of the service; functional quality is the "how."
To obtain a certain desirable outcome from the process
Because the mean and standard deviation are independent of each other.
Is what induces the failure

19. What is Type II Error?
Concluding there has not been an effect/change when there has.
Because the mean and standard deviation are independent of each other.
A random variable that summarizes the information from the sample(s).
If the Response vs. Levels graph if the response lines are not parallel (crossing)

20. ANOVA

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21. What does the abbreviation LCL stand for?
Outside.
Linearity - normality - homoscedasticity - independence.
Lower control limit.
QFD

22. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
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
Upper control limit.
Conformance to specifications.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

23. Which type of SPC measurement is more precise - variable or attribute?
Variable.
A tool that shows the physical flows through a space.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Attribute.

24. Define yield.
Sampling for SPC is done real time.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Observed variation in response is caused by the input
The ratio of outputs to inputs; 1-scrap.

25. Define perceived quality (Garvin's framework).
Brand image.
Attribute
Lean (or JIT).
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

26. In the Service Quality Gap Model - what is Gap 5?
They move closer to the center line.
The gap between what customers expect and the service they receive.
Causes that lead to a particular effect.
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

27. Define serviceability.
Upper control limit.
Speed - courtesy - competence - and ease of repair.
Mistake-proofing.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

28. Failure effect
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The cycle time required to meet demand.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Is the consequence of the failure.

29. What does the abbreviation UCL stand for?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The Japanese national quality award.
Speed - courtesy - competence - and ease of repair.
Upper control limit.

30. Define performance quality.
Define - measure - analyze - improve - control.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The primary operating characteristics of a product.
Prevention and appraisal costs are balanced against internal and external failure.

31. What percentage of a normal distribution lies above the mean?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
50%
The cycle time required to meet demand.
Sort - Set in Order - Shine - Standardize - Sustain

32. What is the role of a master black belt?
To do a capability study for a non-centered process.
To mentor/coach (and sometimes train) black belts.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
They move closer to the center line.

33. If a Cp shows that a process is not capable - should you calculate Cpk?
Lean (or JIT).
No -- if it is not the same - it can only be worse!
To do a capability study for a non-centered process.
What the value of the dependent variable is when the independent variable is zero.

34. What is the role of a black belt?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Scrap - rework - retest - downtime - yield losses - disposition costs.
To manage the Six Sigma project.
Upper control limit.

35. What is the 5S model?
Fractional factorial designs (orthogonal arrays)
Variable.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

36. In the Service Quality Gap Model - what is Gap 2?
Linearity - normality - homoscedasticity - independence.
Supplier - input - process - output - customer.
The gap between what management thinks customers want and the process specifications.
The target number of standard deviations from the mean for specifications.

37. When yields decrease - what are the two effects on contribution?
=sqrt(Σ(x-x-bar)^2)/(n-1))
Fewer good units to sell - increased variable cost/unit.
The gap between what management thinks customers want and the process specifications.
Actual drawings - layouts - maps - etc which show where a defect occurs

38. With Six Sigma capability - how many defects per million opportunities would you see?
Linearity - normality - homoscedasticity - independence.
3.4 (assuming 1.5 sigma shift in the mean)
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
Prevention and appraisal costs are balanced against internal and external failure.

39. What is poka yoke?
Blame.
An assertion or conjecture concerning one or more populations
Define - measure - analyze - improve - control.
Mistake-proofing.

40. Definition of Interaction
Taguchi
The gap between what management thinks customers want and what customers really want.
Causes that lead to a particular effect.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

41. Define durability.
The degree to which a product meets pre-established standards.
Walter A. Shewhart
Mean time to replacement.
Waste.

42. If you can only collect categorical data - what type of SPC charting can you do?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Attribute.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Upper control limit.

43. What is a dashboard?
A tool that shows performance along key dimensions all at once.
To mentor/coach (and sometimes train) black belts.
What the value of the dependent variable is when the independent variable is zero.
Brand image.

44. Non-random patterns (Run Charts)
Shifts - Trends - Repeating patterns - Correlation with known events
Method developed by Ishikawa to graphically display the causes of any given problem
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.

45. FMEA
Lean (or JIT).
A brainstorming tool that shows the connections between ideas.
The ratio of outputs to inputs; 1-scrap.
It looks to minimize the probability of a failure - or to minimize its effects

46. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Lean is waste reduction - Six Sigma is variation reduction.
Sampling for SPC is done real time.
Define - measure - analyze - design - verify.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

47. 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.
Critical to quality.
A diagram that shows the relationships between activities in a project network.
Is what induces the failure

48. One factor at a time (OFAT)
Waste.
Hold all input variables constant except one. Observe the response as you vary the single input.
Attribute
The gap between what is promised and what is delivered.

49. Residual
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
=sqrt((p*(1-p)/n)
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

50. What is Jidoka?
=sqrt((p*(1-p)/n)
Technical quality is the "what" of the service; functional quality is the "how."
Is the consequence of the failure.
Controlling quality at the source.