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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 Deming Prize?
=sqrt(Σ(x-x-bar)^2)/(n-1))
The ability of a process to consistently meet customer specifications.
X-bar-bar
The Japanese national quality award.

2. List two components of prevention cost.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Inventory = throughput x flow time.
Attribute
Upper control limit.

3. Which quality guru developed the concept of loss to society?
Taguchi
Because the mean and standard deviation are independent of each other.
Brand image.
The gap between what management thinks customers want and the process specifications.

4. One factor at a time (OFAT)
Failure Modes and Effects Analysis
Technical quality is the "what" of the service; functional quality is the "how."
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Hold all input variables constant except one. Observe the response as you vary the single input.

5. What is Value Stream Mapping?
Inventory = throughput x flow time.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
A tool that shows where there is waste in a process.

6. Manual Test for Nomality
Shifts - Trends - Repeating patterns - Correlation with known events
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Reliability - Assurance - Responsiveness - Tangibles - Empathy

7. Daniel Test
To monitor a process when measurement by variables is used.
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:
Stratify a particular defect type according to logical criteria
The number of standard deviations some value is from the mean.

8. In a regression - what does the coefficient of the intercept tell you
It's good -- but it's still out of control!
Prevention - appraisal - internal failure - external failure.
What the value of the dependent variable is when the independent variable is zero.
Taguchi

9. Define perceived quality (Garvin's framework).
Consumer risk.
Pleasing to the senses.
The cycle time required to meet demand.
Brand image.

10. Complete this quality phrase: 'Fix the process - not the _____.'
Variable.
Technical quality is the "what" of the service; functional quality is the "how."
Controlling quality at the source.
Blame.

11. Define product reliability.
Critical to quality.
Mean time to failure.
The gap between what customers expect and the service they receive.
= 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

12. In the Service Quality Gap Model - what is Gap 4?
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).
The gap between what is promised and what is delivered.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Fewer good units to sell - increased variable cost/unit.

13. What is Type 1 Error?
Financial - customer - internal process - innovation and learning.
Concluding there has been an effect/change when there has not.
Hold all input variables constant except one. Observe the response as you vary the single input.
99.73%

14. What is the role of a green belt?
Producer risk.
A scatterplot.
To be a member of a Six Sigma project team.
Used to create frequency distribution tally sheets

15. DFMEA
Kaoru Ishikawa.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
The secondary characteristics of a product; "bells and whistles."
Initiated before or at design concept finalization

16. What do you do when a process is out of control?
Look for the assignable cause of non-random variation.
Outside.
Actual drawings - layouts - maps - etc which show where a defect occurs
The target number of standard deviations from the mean for specifications.

17. In the Service Quality Gap Model - what is Gap 1?
The gap between what management thinks customers want and what customers really want.
Observed variation in response is caused by the input
Define - measure - analyze - design - verify.
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

18. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
The gap between what management thinks customers want and the process specifications.
68%
Lean (or JIT).

19. What are the four categories of costs in Juran's framework?
Not necessarily.
To be a member of a Six Sigma project team.
Prevention - appraisal - internal failure - external failure.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

20. What is a Gantt chart?
F_alpha - df(tr) - df (error)
Shows the temporal flow of activities in a project network.
Attribute
Outside.

21. What is a run chart?
A time series plot.
To do a capability study for a non-centered process.
Observed variation in response is caused by the input
If the Response vs. Levels graph if the response lines are not parallel (crossing)

22. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
To monitor a process when measurement by variables is used.
Prevention and appraisal costs are balanced against internal and external failure.
100%

23. What is a dashboard?
It looks to minimize the probability of a failure - or to minimize its effects
5%
A tool that shows performance along key dimensions all at once.
Waste.

24. Definition of Interaction
Financial - customer - internal process - innovation and learning.
To do a capability study for a non-centered process.
QFD
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

25. Define aesthetic quality.
Through producer/consumer negotiation.
Pleasing to the senses.
Define - measure - analyze - improve - control.
Variable.

26. Failure cause
Lower control limit.
0.9^3 or 72.9%
Before production starts
Is what induces the failure

27. In the Service Quality Gap Model - what is Gap 5?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
The gap between what customers expect and the service they receive.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Pleasing to the senses.

28. What quality tool formally incorporates the voice of the customer?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
QFD
= yij - y(bar)i --> value minus sum of that treatment (of row)
Is what induces the failure

29. How are LQL and AQL determined in an acceptance sampling plan?
Fractional factorial designs (orthogonal arrays)
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
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Through producer/consumer negotiation.

30. Cause and Effect Diagrams
A tool that shows the physical flows through a space.
A tool that shows where there is waste in a process.
Method developed by Ishikawa to graphically display the causes of any given problem
F_alpha - df(tr) - df (error)

31. Define takt time.
To do a capability study for a non-centered process.
The cycle time required to meet demand.
Fractional factorial designs (orthogonal arrays)
Outside.

32. One factor at a time (OFAT)
Shows the temporal flow of activities in a project network.
Attribute
Upper control limit.
Observed variation in response is caused by the input

33. Test for constant variance
The gap between what customers expect and the service they receive.
=sqrt(Σ(x-x-bar)^2)/(n-1))
No -- if it is not the same - it can only be worse!
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.

34. Stratified defect check sheets
Lower skill requirements - faster - less chance for error.
Stratify a particular defect type according to logical criteria
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Assigns scores to weighted criteria for each project under consideration.

35. What does a project prioritization matrix do?
Sort - Set in Order - Shine - Standardize - Sustain
They move closer to the center line.
Assigns scores to weighted criteria for each project under consideration.
Define - measure - analyze - design - verify.

36. In the Service Quality Gap Model - what is Gap 2?
The gap between what management thinks customers want and the process specifications.
Organize ideas into meaningful categories by recognizing their underlying similarity
False - because each machine will have different natural tolerances.
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.

37. FMEA
A time series plot.
A scatterplot.
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
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

38. What is the center line of an X-bar chart?
They move closer to the center line.
X-bar-bar
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Is the consequence of the failure.

39. What does Crosby say about benchmarking?
F_alpha - df(tr) - df (error)
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Shifts - Trends - Repeating patterns - Correlation with known events
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

40. List two components of internal failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Variable.
0.9^3 or 72.9%
Prevention - appraisal - internal failure - external failure.

41. Affinity Diagrams
Observed variation in response is caused by the input
Organize ideas into meaningful categories by recognizing their underlying similarity
Taguchi
Central Limit Theorem

42. Who developed the fishbone diagram?
Organize ideas into meaningful categories by recognizing their underlying similarity
The manager in charge of a process being improved in a Six Sigma project.
Kaoru Ishikawa.
Prevention - appraisal - internal failure - external failure.

43. What does the abbreviation UCL stand for?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Upper control limit.
Concluding there has been an effect/change when there has not.
68%

44. In a regression - what does the p value of F tell you?
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).
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
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

45. With Six Sigma capability - how many defects per million opportunities would you see?
Shifts - Trends - Repeating patterns - Correlation with known events
Deming.
To monitor a process when measurement by variables is used.
3.4 (assuming 1.5 sigma shift in the mean)

46. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
99.73%
A brainstorming tool that shows the connections between ideas.
Look for the assignable cause of non-random variation.
Mean time to replacement.

47. What size should samples be for attribute SPC?
Deming.
Large enough to find two of the attribute - on average.
Walter A. Shewhart
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

48. Define features.
Variable.
Lower control limit.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
The secondary characteristics of a product; "bells and whistles."

49. List two appraisal costs.
Lower control limit.
95%
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

50. What is Little's Law?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Inventory = throughput x flow time.
An assertion or conjecture concerning one or more populations
Producer risk.