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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. DOE
Rapid improvement process.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Fractional factorial designs (orthogonal arrays)
The number of standard deviations some value is from the mean.

2. What is a run chart?
A time series plot.
Lean is waste reduction - Six Sigma is variation reduction.
To obtain a certain desirable outcome from the process
Outside.

3. Residual
The gap between what customers expect and the service they receive.
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
The target number of standard deviations from the mean for specifications.

4. What is the formula for standard deviation?
=sqrt(Σ(x-x-bar)^2)/(n-1))
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Conformance to specifications.

5. One factor at a time (OFAT)
Observed variation in response is caused by the input
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Deming.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

6. What is the role of a green belt?
To be a member of a Six Sigma project team.
Not necessarily.
Because the mean and standard deviation are independent of each other.
The gap between what management thinks customers want and the process specifications.

7. Define benchmarking.
A tool that shows the physical flows through a space.
Studying firms with the best performance in a particular area.
False - because each machine will have different natural tolerances.
Producer risk.

8. Detection Criteria Ranking
Kaoru Ishikawa.
10 if Almost impossible to detect
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Upper control limit.

9. What is the 5S model?
= yij - y(bar)i --> value minus sum of that treatment (of row)
Conformance to specifications.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Central Limit Theorem

10. Define features.
The secondary characteristics of a product; "bells and whistles."
Variable.
Technical quality is the "what" of the service; functional quality is the "how."
Not necessarily.

11. Define perceived quality (Garvin's framework).
Brand image.
The primary operating characteristics of a product.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Central Limit Theorem

12. List two components of prevention cost.
Prevention and appraisal costs are balanced against internal and external failure.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
68%
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

13. What is the role of a master black belt?
To mentor/coach (and sometimes train) black belts.
The House of Quality.
The Japanese national quality award.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

14. Failure effect
Controlling quality at the source.
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
Assigns scores to weighted criteria for each project under consideration.
Is the consequence of the failure.

15. Defect location check sheets
Walter A. Shewhart
Actual drawings - layouts - maps - etc which show where a defect occurs
Linearity - normality - homoscedasticity - independence.
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

16. Failure Mode
Method developed by Ishikawa to graphically display the causes of any given problem
Deming.
Someone who is consistently against virtually everything.
Is the way in which the failure is manifested.

17. What happens to control limits on an SPC chart when sample size is increased?
They move closer to the center line.
The manager in charge of a process being improved in a Six Sigma project.
Mistake-proofing.
Attribute

18. DFMEA
Initiated before or at design concept finalization
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
A tool that shows where there is waste in a process.
What the value of the dependent variable is when the independent variable is zero.

19. In the Service Quality Gap Model - what is Gap 2?
The gap between what management thinks customers want and the process specifications.
Variable.
50%
A diagram that shows the relationships between activities in a project network.

20. Define conformance quality.
The degree to which a product meets pre-established standards.
Producer risk.
A time series plot.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

21. How are LQL and AQL determined in an acceptance sampling plan?
Through producer/consumer negotiation.
The gap between what management thinks customers want and the process specifications.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
If the Response vs. Levels graph if the response lines are not parallel (crossing)

22. What are the four perspectives of the Balanced Scorecard?
To mentor/coach (and sometimes train) black belts.
Financial - customer - internal process - innovation and learning.
Lower control limit.
It's good -- but it's still out of control!

23. What is poka yoke?
Speed - courtesy - competence - and ease of repair.
Actual drawings - layouts - maps - etc which show where a defect occurs
Mistake-proofing.
Mean time to failure.

24. What is Type II Error?
Shifts - Trends - Repeating patterns - Correlation with known events
Concluding there has not been an effect/change when there has.
A tool that shows where there is waste in a process.
Consumer risk.

25. Failure cause
Inventory = throughput x flow time.
To obtain a certain desirable outcome from the process
95%
Is what induces the failure

26. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
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
Reliability - Assurance - Responsiveness - Tangibles - Empathy

27. Why do you need two control charts for variables SPC?
Fewer good units to sell - increased variable cost/unit.
Define - measure - analyze - design - verify.
Because the mean and standard deviation are independent of each other.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

28. List Garvin's eight dimensions of product quality.
The gap between what management thinks customers want and what customers really want.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Attribute
Deming.

29. For what is a p-chart used?
Workers - machines - materials.
Fewer good units to sell - increased variable cost/unit.
The manager in charge of a process being improved in a Six Sigma project.
To monitor a process when measurement by attribute is used.

30. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Lower skill requirements - faster - less chance for error.
Fractional factorial designs (orthogonal arrays)
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

31. Which quality guru developed the concept of loss to society?
Taguchi
The number of standard deviations some value is from the mean.
Deming.
It's good -- but it's still out of control!

32. 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
Fitness for use.
To monitor a process when measurement by variables is used.
95%

33. Regression
Represents the behavior of a process
Lower skill requirements - faster - less chance for error.
Stratify a particular defect type according to logical criteria
The gap between what is promised and what is delivered.

34. What quality tool formally incorporates the voice of the customer?
QFD
To obtain a certain desirable outcome from the process
Speed - courtesy - competence - and ease of repair.
X-bar-bar

35. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Walter A. Shewhart
The House of Quality.
A random variable that summarizes the information from the sample(s).

36. What are the three main categories of assignable cause?
Workers - machines - materials.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Financial - customer - internal process - innovation and learning.

37. Define yield.
A tool that shows where there is waste in a process.
Assigns scores to weighted criteria for each project under consideration.
The ratio of outputs to inputs; 1-scrap.
The House of Quality.

38. Based on what principal can we use the normal distribution assumptions for SPC?
The degree to which a product meets pre-established standards.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Central Limit Theorem
What the value of the dependent variable is when the independent variable is zero.

39. Who first studied randomness in industrial processes
No -- if it is not the same - it can only be worse!
No -- only if the process is also capable.
To mentor/coach (and sometimes train) black belts.
Walter A. Shewhart

40. When yields decrease - what are the two effects on contribution?
Attribute
Fewer good units to sell - increased variable cost/unit.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The gap between what management thinks customers want and the process specifications.

41. What is the role of a black belt?
Fishbone - cause-and-effect diagram.
To manage the Six Sigma project.
The primary operating characteristics of a product.
Actual drawings - layouts - maps - etc which show where a defect occurs

42. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
95%
The ratio of outputs to inputs; 1-scrap.
0.9^3 or 72.9%
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

43. In the Service Quality Gap Model - what is Gap 4?
Lean is waste reduction - Six Sigma is variation reduction.
The gap between what is promised and what is delivered.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Fishbone - cause-and-effect diagram.

44. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
68%
QFD
Fractional factorial designs (orthogonal arrays)
Assigns scores to weighted criteria for each project under consideration.

45. What are the Five Dimensions of Service Quality?
Concluding there has not been an effect/change when there has.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
3.4 (assuming 1.5 sigma shift in the mean)
Reliability - Assurance - Responsiveness - Tangibles - Empathy

46. What is a spaghetti diagram?
The gap between what customers expect and the service they receive.
Producer risk.
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
A tool that shows the physical flows through a space.

47. What is a histogram?
The ability of a process to consistently meet customer specifications.
To do a capability study for a non-centered process.
A random variable that summarizes the information from the sample(s).
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

48. Manual Test for Nomality
Mean time to replacement.
The degree to which a product meets pre-established standards.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Method developed by Ishikawa to graphically display the causes of any given problem

49. TWO-DIMENTIONAL SCATTER PLOT
Mistake-proofing.
The degree to which a product meets pre-established standards.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Failure Modes and Effects Analysis

50. If you have calculated a Cpk - should you also calculate a Cp?
Someone who is consistently against virtually everything.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median