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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. Daniel Test
Assigns scores to weighted criteria for each project under consideration.
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:
Hold all input variables constant except one. Observe the response as you vary the single input.
=sqrt(Σ(x-x-bar)^2)/(n-1))

2. Failure Mode
Variable.
Mistake-proofing.
Is the way in which the failure is manifested.
No -- the variation also has to be random and "expected."

3. Defect check sheets
Look for the assignable cause of non-random variation.
Different types of defects are listed (used for Pareto chart)
95%
The target number of standard deviations from the mean for specifications.

4. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
QFD
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Lower skill requirements - faster - less chance for error.
Lower control limit.

5. What does the abbreviation LCL stand for?
Deming.
Lower control limit.
10 for Hazardous without warning 1 for none
Before production starts

6. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
100%
95%
Failure Modes and Effects Analysis
They move closer to the center line.

7. List two components of external failure.
Defects Per Million Opportunities
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Walter A. Shewhart
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

8. What are the three main categories of assignable cause?
Is the way in which the failure is manifested.
68%
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Workers - machines - materials.

9. List two components of internal failure.
Shifts - Trends - Repeating patterns - Correlation with known events
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Scrap - rework - retest - downtime - yield losses - disposition costs.
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

10. 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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11. Pareto Analysis
Shows the temporal flow of activities in a project network.
Variable.
No -- the variation also has to be random and "expected."
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

12. What is the center line of an X-bar chart?
50%
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
A diagram that shows the relationships between activities in a project network.
X-bar-bar

13. Simple Regression Analysis (one factor regression model)
Mean time to replacement.
Because the mean and standard deviation are independent of each other.
Defects Per Million Opportunities
= 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

14. Detection Criteria Ranking
10 if Almost impossible to detect
It looks to minimize the probability of a failure - or to minimize its effects
A brainstorming tool that shows the connections between ideas.
Mean time to replacement.

15. Creating a Run Chart
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Initiated before or at design concept finalization
Consumer risk.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

16. In Juran's Cost of Quality model - which categories of costs balance which other categories?
No -- only if the process is also capable.
Prevention and appraisal costs are balanced against internal and external failure.
The gap between what management thinks customers want and what customers really want.
Attribute.

17. What are the four categories of costs in Juran's framework?
The target number of standard deviations from the mean for specifications.
Prevention - appraisal - internal failure - external failure.
The gap between what customers expect and the service they receive.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

18. In the Service Quality Gap Model - what is Gap 4?
Hold all input variables constant except one. Observe the response as you vary the single input.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
An assertion or conjecture concerning one or more populations
The gap between what is promised and what is delivered.

19. What percentage of a normal distribution lies above the mean?
50%
The primary operating characteristics of a product.
Fishbone - cause-and-effect diagram.
Pleasing to the senses.

20. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
The gap between what management thinks customers want and what customers really want.
68%
A diagram that shows the relationships between activities in a project network.
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.

21. Why do you need two control charts for variables SPC?
5%
The gap between what management thinks customers want and what customers really want.
Prevention - appraisal - internal failure - external failure.
Because the mean and standard deviation are independent of each other.

22. What is a Gage R&R?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
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).
To mentor/coach (and sometimes train) black belts.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

23. What does DMAIC stand for?
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).
Before production starts
3.4 (assuming 1.5 sigma shift in the mean)
Define - measure - analyze - improve - control.

24. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
68%
95%
What the value of the dependent variable is when the independent variable is zero.

25. When is Cpk used?
To be a member of a Six Sigma project team.
To do a capability study for a non-centered process.
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).
It's good -- but it's still out of control!

26. How are LQL and AQL determined in an acceptance sampling plan?
What the value of the dependent variable is when the independent variable is zero.
Mistake-proofing.
Through producer/consumer negotiation.
The gap between what management thinks customers want and what customers really want.

27. What is a Pareto chart?
A descending order-sorted bar chart with a cumulative percentage line.
Different types of defects are listed (used for Pareto chart)
Is the way in which the failure is manifested.
Waste.

28. Risk Priority Number RPN
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Linearity - normality - homoscedasticity - independence.
To manage the Six Sigma project.
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

29. Name the structure associated with Quality Function Deployment.
3.4 (assuming 1.5 sigma shift in the mean)
The gap between what is promised and what is delivered.
A descending order-sorted bar chart with a cumulative percentage line.
The House of Quality.

30. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
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.
Controlling quality at the source.
Variable.
Fitness for use.

31. FMEA
0.9^3 or 72.9%
68%
Upper control limit.
It looks to minimize the probability of a failure - or to minimize its effects

32. What is written on the "spines" of a fishbone diagram?
Causes that lead to a particular effect.
Lower skill requirements - faster - less chance for error.
The target number of standard deviations from the mean for specifications.
Concluding there has been an effect/change when there has not.

33. What is Kaizen?
Rapid improvement process.
Attribute.
Producer risk.
Consumer risk.

34. Who first studied randomness in industrial processes
Prevention - appraisal - internal failure - external failure.
Is the consequence of the failure.
Walter A. Shewhart
Reliability - Assurance - Responsiveness - Tangibles - Empathy

35. Affinity Diagrams
The gap between specifications and how service is performed.
Organize ideas into meaningful categories by recognizing their underlying similarity
Prevention and appraisal costs are balanced against internal and external failure.
To mentor/coach (and sometimes train) black belts.

36. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
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
The cycle time required to meet demand.
Studying firms with the best performance in a particular area.

37. Manual Test for Nomality
The US national quality award.
The gap between what is promised and what is delivered.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Hold all input variables constant except one. Observe the response as you vary the single input.

38. What is FMEA?
Fractional factorial designs (orthogonal arrays)
Failure Modes and Effects Analysis
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Shifts - Trends - Repeating patterns - Correlation with known events

39. What is DMADV?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Define - measure - analyze - design - verify.
They move closer to the center line.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

40. Effect ranking (Severity of the Defect)
If the Response vs. Levels graph if the response lines are not parallel (crossing)
10 for Hazardous without warning 1 for none
Represents the behavior of a process
Central Limit Theorem

41. What is Value Stream Mapping?
False - because each machine will have different natural tolerances.
Shifts - Trends - Repeating patterns - Correlation with known events
A tool that shows where there is waste in a process.
Observed variation in response is caused by the input

42. Complete this quality phrase: 'Fix the process - not the _____.'
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Blame.
Workers - machines - materials.
The ability of a process to consistently meet customer specifications.

43. Define aesthetic quality.
Define - measure - analyze - improve - control.
Pleasing to the senses.
Causes that lead to a particular effect.
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

44. List Garvin's eight dimensions of product quality.
Pleasing to the senses.
A tool that shows the physical flows through a space.
Waste.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

45. F value
F_alpha - df(tr) - df (error)
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A brainstorming tool that shows the connections between ideas.

46. 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 monitor a process when measurement by attribute is used.
Defects Per Million Opportunities
=sqrt((p*(1-p)/n)
False - because each machine will have different natural tolerances.

47. One factor at a time (OFAT)
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Look for the assignable cause of non-random variation.
Hold all input variables constant except one. Observe the response as you vary the single input.

48. If you can only collect categorical data - what type of SPC charting can you do?
Inventory = throughput x flow time.
Attribute.
To do a capability study for a non-centered process.
5%

49. FMEA
A random variable that summarizes the information from the sample(s).
An assertion or conjecture concerning one or more populations
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
3.4 (assuming 1.5 sigma shift in the mean)

50. Cause and Effect Diagrams
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Is the consequence of the failure.
Method developed by Ishikawa to graphically display the causes of any given problem