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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. What is the role of a black belt?
Define - measure - analyze - design - verify.
To manage the Six Sigma project.
A time series plot.
Is what induces the failure

2. Defect check sheets
Pleasing to the senses.
Technical quality is the "what" of the service; functional quality is the "how."
The gap between what customers expect and the service they receive.
Different types of defects are listed (used for Pareto chart)

3. What is Type 1 Error?
Central Limit Theorem
Concluding there has been an effect/change when there has not.
Causes that lead to a particular effect.
Linearity - normality - homoscedasticity - independence.

4. Detection Criteria Ranking
The manager in charge of a process being improved in a Six Sigma project.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
10 if Almost impossible to detect
Producer risk.

5. Define takt time.
Concluding there has not been an effect/change when there has.
The cycle time required to meet demand.
The gap between specifications and how service is performed.
The secondary characteristics of a product; "bells and whistles."

6. What is an affinity diagram?
95%
The ratio of outputs to inputs; 1-scrap.
A brainstorming tool that shows the connections between ideas.
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

7. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Define - measure - analyze - improve - control.
Waste.
No -- the variation also has to be random and "expected."
They move closer to the center line.

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

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9. What happens to control limits on an SPC chart when sample size is increased?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Pleasing to the senses.
They move closer to the center line.

10. Uses of regression
What the value of the dependent variable is when the independent variable is zero.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Represents the behavior of a process

11. Define serviceability.
Speed - courtesy - competence - and ease of repair.
Not necessarily.
Is the consequence of the failure.
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

12. Who is a process owner?
Causes that lead to a particular effect.
The manager in charge of a process being improved in a Six Sigma project.
Observed variation in response is caused by the input
Failure Modes and Effects Analysis

13. List Garvin's eight dimensions of product quality.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
A diagram that shows the relationships between activities in a project network.
Is the way in which the failure is manifested.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

14. What is the role of a master black belt?
A random variable that summarizes the information from the sample(s).
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
To mentor/coach (and sometimes train) black belts.
The secondary characteristics of a product; "bells and whistles."

15. What size should samples be for attribute SPC?
Deming.
95%
Large enough to find two of the attribute - on average.
No -- the variation also has to be random and "expected."

16. Your production process meets customer specifications. Is your process in control?
False - because each machine will have different natural tolerances.
= 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
To monitor a process when measurement by variables is used.
Not necessarily.

17. In the Service Quality Gap Model - what is Gap 5?
The gap between what customers expect and the service they receive.
Someone who is consistently against virtually everything.
Hold all input variables constant except one. Observe the response as you vary the single input.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

18. Process check sheets
The primary operating characteristics of a product.
Supplier - input - process - output - customer.
Because the mean and standard deviation are independent of each other.
Used to create frequency distribution tally sheets

19. For what is a p-chart used?
To monitor a process when measurement by attribute is used.
The gap between what management thinks customers want and the process specifications.
10 if Almost impossible to detect
To monitor a process when measurement by variables is used.

20. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Upper control limit.
Shifts - Trends - Repeating patterns - Correlation with known events
99.73%
Sampling for SPC is done real time.

21. Cause and Effect Diagrams
No -- the variation also has to be random and "expected."
Method developed by Ishikawa to graphically display the causes of any given problem
Sort - Set in Order - Shine - Standardize - Sustain
Outside.

22. What does the abbreviation UCL stand for?
False - because each machine will have different natural tolerances.
A tool that shows performance along key dimensions all at once.
Upper control limit.
Controlling quality at the source.

23. Failure Mode
= 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
Is the way in which the failure is manifested.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Someone who is consistently against virtually everything.

24. Define perceived quality (Garvin's framework).
Define - measure - analyze - design - verify.
Fitness for use.
A descending order-sorted bar chart with a cumulative percentage line.
Brand image.

25. DFMEA
It's good -- but it's still out of control!
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Initiated before or at design concept finalization
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).

26. Failure effect
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The gap between what management thinks customers want and the process specifications.
Is the consequence of the failure.
The US national quality award.

27. Who developed the fishbone diagram?
Kaoru Ishikawa.
Is the way in which the failure is manifested.
3.4 (assuming 1.5 sigma shift in the mean)
The gap between what customers expect and the service they receive.

28. In the Service Quality Gap Model - what is Gap 4?
The gap between what is promised and what is delivered.
Attribute.
The gap between what customers expect and the service they receive.
The US national quality award.

29. What graphical tool is used to show the relationship between two numerical variables?
Observed variation in response is caused by the input
A scatterplot.
A tool that shows performance along key dimensions all at once.
Attribute.

30. What does the abbreviation LCL stand for?
Because the mean and standard deviation are independent of each other.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Lower control limit.
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

31. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Method developed by Ishikawa to graphically display the causes of any given problem
=sqrt((p*(1-p)/n)
No -- only if the process is also capable.
95%

32. If a Cp shows that a process is not capable - should you calculate Cpk?
Lean (or JIT).
0.9^3 or 72.9%
No -- if it is not the same - it can only be worse!
=sqrt(Σ(x-x-bar)^2)/(n-1))

33. What is poka yoke?
To manage the Six Sigma project.
What the value of the dependent variable is when the independent variable is zero.
Mistake-proofing.
Central Limit Theorem

34. In a regression - what does the p value of F tell you?
Fractional factorial designs (orthogonal arrays)
10 if Almost impossible to detect
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).
Stratify a particular defect type according to logical criteria

35. What are the four categories of costs in Juran's framework?
Prevention - appraisal - internal failure - external failure.
Before production starts
Workers - machines - materials.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

36. If a three-stage process has 90% yields at each stage - what is the overall yield?
0.9^3 or 72.9%
The degree to which a product meets pre-established standards.
Concluding there has not been an effect/change when there has.
Fitness for use.

37. What is the difference between the way sampling is done for SPC and for acceptance sampling?
The secondary characteristics of a product; "bells and whistles."
Can't tell without a Range chart.
Sampling for SPC is done real time.
Inventory = throughput x flow time.

38. List two components of internal failure.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Used to create frequency distribution tally sheets
Scrap - rework - retest - downtime - yield losses - disposition costs.
Inventory = throughput x flow time.

39. Based on what principal can we use the normal distribution assumptions for SPC?
Through producer/consumer negotiation.
The US national quality award.
The primary operating characteristics of a product.
Central Limit Theorem

40. Residual(eij)
The ratio of outputs to inputs; 1-scrap.
False - because each machine will have different natural tolerances.
= yij - y(bar)i --> value minus sum of that treatment (of row)
3.4 (assuming 1.5 sigma shift in the mean)

41. Advantages of DOE
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
Not necessarily.
Failure Modes and Effects Analysis
If the Response vs. Levels graph if the response lines are not parallel (crossing)

42. Presence of interaction effect
Different types of defects are listed (used for Pareto chart)
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Workers - machines - materials.
A brainstorming tool that shows the connections between ideas.

43. List two components of external failure.
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:
It's good -- but it's still out of control!
Not necessarily.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

44. To what does the Six in Six Sigma relate?
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).
X-bar-bar
The target number of standard deviations from the mean for specifications.
Critical to quality.

45. What is FMEA?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Inventory = throughput x flow time.
Failure Modes and Effects Analysis
Lean (or JIT).

46. What is a Gage R&R?
Define - measure - analyze - design - verify.
Method developed by Ishikawa to graphically display the causes of any given problem
The cycle time required to meet demand.
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).

47. What is the difference between Lean and Six Sigma?
Lean is waste reduction - Six Sigma is variation reduction.
Organize ideas into meaningful categories by recognizing their underlying similarity
Assigns scores to weighted criteria for each project under consideration.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

48. What is written on the "spines" of a fishbone diagram?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
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.
The cycle time required to meet demand.

49. Does it ever make sense to accept a job when a process is incapable?
Represents the behavior of a process
Concluding there has been an effect/change when there has not.
Lean is waste reduction - Six Sigma is variation reduction.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

50. Complete this quality phrase: 'Fix the process - not the _____.'
Blame.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Supplier - input - process - output - customer.
50%