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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 are the four categories of costs in Juran's framework?
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 - appraisal - internal failure - external failure.
To do a capability study for a non-centered process.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

2. Pareto Analysis
To obtain a certain desirable outcome from the process
Outside.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
False - because each machine will have different natural tolerances.

3. Which quality guru developed the concept of loss to society?
Actual drawings - layouts - maps - etc which show where a defect occurs
Taguchi
Kaoru Ishikawa.
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).

4. What is Type II Error?
Shifts - Trends - Repeating patterns - Correlation with known events
Assigns scores to weighted criteria for each project under consideration.
Concluding there has not been an effect/change when there has.
Prevention and appraisal costs are balanced against internal and external failure.

5. What are the four regression assumptions?
No -- if it is not the same - it can only be worse!
Linearity - normality - homoscedasticity - independence.
Supplier - input - process - output - customer.
=sqrt((p*(1-p)/n)

6. What size should samples be for attribute SPC?
The number of standard deviations some value is from the mean.
Large enough to find two of the attribute - on average.
Observed variation in response is caused by the input
What the value of the dependent variable is when the independent variable is zero.

7. What quality tool formally incorporates the voice of the customer?
Linearity - normality - homoscedasticity - independence.
Hold all input variables constant except one. Observe the response as you vary the single input.
Scrap - rework - retest - downtime - yield losses - disposition costs.
QFD

8. Regression
Represents the behavior of a process
Lean (or JIT).
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).
Kaoru Ishikawa.

9. What is Value Stream Mapping?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
No -- if it is not the same - it can only be worse!
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 tool that shows where there is waste in a process.

10. Define conformance quality.
The degree to which a product meets pre-established standards.
Sort - Set in Order - Shine - Standardize - Sustain
Upper control limit.
Controlling quality at the source.

11. Test for Independence
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
Assigns scores to weighted criteria for each project under consideration.
Technical quality is the "what" of the service; functional quality is the "how."
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).

12. What is the role of a master black belt?
Mean time to replacement.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
To mentor/coach (and sometimes train) black belts.
Actual drawings - layouts - maps - etc which show where a defect occurs

13. Failure Mode
= yij - y(bar)i --> value minus sum of that treatment (of row)
Attribute
No -- the variation also has to be random and "expected."
Is the way in which the failure is manifested.

14. F value
100%
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Mean time to failure.
F_alpha - df(tr) - df (error)

15. What is a spaghetti diagram?
Prevention - appraisal - internal failure - external failure.
A tool that shows the physical flows through a space.
To do a capability study for a non-centered process.
The secondary characteristics of a product; "bells and whistles."

16. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
Mean time to replacement.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

17. 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?
False - because each machine will have different natural tolerances.
A descending order-sorted bar chart with a cumulative percentage line.
Lower control limit.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

18. What do you do when a process is out of control?
The gap between specifications and how service is performed.
Look for the assignable cause of non-random variation.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Sort - Set in Order - Shine - Standardize - Sustain

19. Non-random patterns (Run Charts)
Represents the behavior of a process
To monitor a process when measurement by variables is used.
Attribute.
Shifts - Trends - Repeating patterns - Correlation with known events

20. What is Jidoka?
A random variable that summarizes the information from the sample(s).
99.73%
Controlling quality at the source.
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

21. Complete this quality phrase: 'Fix the process - not the _____.'
Blame.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Concluding there has been an effect/change when there has not.
Technical quality is the "what" of the service; functional quality is the "how."

22. What is process capability?
Mean time to failure.
Taguchi
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The ability of a process to consistently meet customer specifications.

23. What is a Pareto chart?
Rapid improvement process.
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
To mentor/coach (and sometimes train) black belts.
A descending order-sorted bar chart with a cumulative percentage line.

24. Process check sheets
A time series plot.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Used to create frequency distribution tally sheets
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

25. Define durability.
A tool that shows the physical flows through a space.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Mean time to replacement.
Inventory = throughput x flow time.

26. What are the 5 Ss?
Supplier - input - process - output - customer.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
A tool that shows the physical flows through a space.
Sort - Set in Order - Shine - Standardize - Sustain

27. What is muda
Waste.
Causes that lead to a particular effect.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Speed - courtesy - competence - and ease of repair.

28. How does Juran define quality?
Walter A. Shewhart
Attribute
Define - measure - analyze - improve - control.
Fitness for use.

29. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Not necessarily.
A time series plot.
Variable.
It's good -- but it's still out of control!

30. List two appraisal costs.
Stratify a particular defect type according to logical criteria
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The secondary characteristics of a product; "bells and whistles."
Workers - machines - materials.

31. DFMEA
Hold all input variables constant except one. Observe the response as you vary the single input.
QFD
The number of standard deviations some value is from the mean.
Initiated before or at design concept finalization

32. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
To manage the Six Sigma project.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Lean (or JIT).
Because the mean and standard deviation are independent of each other.

33. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
A diagram that shows the relationships between activities in a project network.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Look for the assignable cause of non-random variation.
Outside.

34. FMEA
Large enough to find two of the attribute - on average.
Inventory = throughput x flow time.
It looks to minimize the probability of a failure - or to minimize its effects
A scatterplot.

35. How are LQL and AQL determined in an acceptance sampling plan?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Through producer/consumer negotiation.
Represents the behavior of a process
Stratify a particular defect type according to logical criteria

36. Does it ever make sense to accept a job when a process is incapable?
Shifts - Trends - Repeating patterns - Correlation with known events
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
The Japanese national quality award.
Taguchi

37. Who first studied randomness in industrial processes
Walter A. Shewhart
The number of standard deviations some value is from the mean.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

38. What are the Five Dimensions of Service Quality?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
It looks to minimize the probability of a failure - or to minimize its effects

39. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
95%
Can't tell without a Range chart.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Variable.

40. What is FMEA?
A descending order-sorted bar chart with a cumulative percentage line.
Pleasing to the senses.
Failure Modes and Effects Analysis
Controlling quality at the source.

41. What is a dashboard?
To obtain a certain desirable outcome from the process
A tool that shows performance along key dimensions all at once.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Not necessarily.

42. What happens to control limits on an SPC chart when sample size is increased?
The degree to which a product meets pre-established standards.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Controlling quality at the source.
They move closer to the center line.

43. Cause and Effect Diagrams
Define - measure - analyze - improve - control.
Method developed by Ishikawa to graphically display the causes of any given problem
To mentor/coach (and sometimes train) black belts.
The ratio of outputs to inputs; 1-scrap.

44. In the Service Quality Gap Model - what is Gap 1?
0.9^3 or 72.9%
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
5%
The gap between what management thinks customers want and what customers really want.

45. Statistical Hypothesis
Prevention and appraisal costs are balanced against internal and external failure.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
An assertion or conjecture concerning one or more populations
Financial - customer - internal process - innovation and learning.

46. What is DMADV?
Concluding there has not been an effect/change when there has.
To obtain a certain desirable outcome from the process
Used to create frequency distribution tally sheets
Define - measure - analyze - design - verify.

47. The Test Statistic (TS)
Lower skill requirements - faster - less chance for error.
95%
A random variable that summarizes the information from the sample(s).
Lean (or JIT).

48. What is poka yoke?
No -- the variation also has to be random and "expected."
A brainstorming tool that shows the connections between ideas.
Initiated before or at design concept finalization
Mistake-proofing.

49. What is a histogram?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
False - because each machine will have different natural tolerances.
No -- only if the process is also capable.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

50. What does DMAIC stand for?
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
Variable.
A scatterplot.
Define - measure - analyze - improve - control.