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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 DPMO?
To monitor a process when measurement by variables is used.
The gap between what management thinks customers want and what customers really want.
Defects Per Million Opportunities
Speed - courtesy - competence - and ease of repair.

2. In the Service Quality Gap Model - what is Gap 2?
Technical quality is the "what" of the service; functional quality is the "how."
Is the way in which the failure is manifested.
Shifts - Trends - Repeating patterns - Correlation with known events
The gap between what management thinks customers want and the process specifications.

3. Affinity Diagrams
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Method developed by Ishikawa to graphically display the causes of any given problem
Hold all input variables constant except one. Observe the response as you vary the single input.
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

4. What percentage of a normal distribution lies above the mean?
The gap between what management thinks customers want and the process specifications.
No -- only if the process is also capable.
50%
No -- the variation also has to be random and "expected."

5. If you can only collect categorical data - what type of SPC charting can you do?
Lower control limit.
Assigns scores to weighted criteria for each project under consideration.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Attribute.

6. What is a dashboard?
0.9^3 or 72.9%
A tool that shows performance along key dimensions all at once.
Through producer/consumer negotiation.
Large enough to find two of the attribute - on average.

7. Test for Independence
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Workers - machines - materials.
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
= yij - y(bar)i --> value minus sum of that treatment (of row)

8. Define features.
Lower skill requirements - faster - less chance for error.
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.
Supplier - input - process - output - customer.
The secondary characteristics of a product; "bells and whistles."

9. Who developed the fishbone diagram?
Kaoru Ishikawa.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
The US national quality award.

10. What is Kaizen?
Method developed by Ishikawa to graphically display the causes of any given problem
Mean time to failure.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Rapid improvement process.

11. Process check sheets
Used to create frequency distribution tally sheets
Different types of defects are listed (used for Pareto chart)
QFD
Fishbone - cause-and-effect diagram.

12. Name the structure associated with Quality Function Deployment.
0.9^3 or 72.9%
A tool that shows where there is waste in a process.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
The House of Quality.

13. List two components of internal failure.
What the value of the dependent variable is when the independent variable is zero.
Variable.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Lean is waste reduction - Six Sigma is variation reduction.

14. Failure Mode
The gap between specifications and how service is performed.
The manager in charge of a process being improved in a Six Sigma project.
Is the way in which the failure is manifested.
The number of standard deviations some value is from the mean.

15. Failure effect
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Is the consequence of the failure.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Linearity - normality - homoscedasticity - independence.

16. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
Kaoru Ishikawa.
Inventory = throughput x flow time.
They move closer to the center line.

17. Which quality guru developed the concept of loss to society?
Initiated before or at design concept finalization
It looks to minimize the probability of a failure - or to minimize its effects
3.4 (assuming 1.5 sigma shift in the mean)
Taguchi

18. What quality tool formally incorporates the voice of the customer?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Supplier - input - process - output - customer.
False - because each machine will have different natural tolerances.
QFD

19. What does SIPOC stand for?
Supplier - input - process - output - customer.
Before production starts
To manage the Six Sigma project.
Speed - courtesy - competence - and ease of repair.

20. Simple Regression Analysis (one factor regression model)
50%
Consumer risk.
Workers - machines - materials.
= 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

21. List two appraisal costs.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Sampling for SPC is done real time.
The primary operating characteristics of a product.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

22. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
To monitor a process when measurement by attribute is used.
99.73%
Method developed by Ishikawa to graphically display the causes of any given problem
Rapid improvement process.

23. Non-random patterns (Run Charts)
Shifts - Trends - Repeating patterns - Correlation with known events
Upper control limit.
Outside.
A tool that shows the physical flows through a space.

24. For what is an x-bar chart used?
To monitor a process when measurement by variables is used.
The degree to which a product meets pre-established standards.
= yij - y(bar)i --> value minus sum of that treatment (of row)
It's good -- but it's still out of control!

25. In the Service Quality Gap Model - what is Gap 3?
The gap between specifications and how service is performed.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Attribute
Used to create frequency distribution tally sheets

26. Define takt time.
No -- the variation also has to be random and "expected."
The cycle time required to meet demand.
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

27. Failure cause
Is what induces the failure
Walter A. Shewhart
Variable.
The ratio of outputs to inputs; 1-scrap.

28. What is a run chart?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
A time series plot.
Causes that lead to a particular effect.
False - because each machine will have different natural tolerances.

29. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
95%
The degree to which a product meets pre-established standards.
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
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:

30. What graphical tool is used to show the relationship between two numerical variables?
To monitor a process when measurement by variables is used.
Can't tell without a Range chart.
A scatterplot.
Shows the temporal flow of activities in a project network.

31. What is an affinity diagram?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
p-bar - the long-run percent defective.
False - because each machine will have different natural tolerances.
A brainstorming tool that shows the connections between ideas.

32. Daniel Test
A scatterplot.
The ratio of outputs to inputs; 1-scrap.
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:
Initiated before or at design concept finalization

33. Regression
99.73%
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Represents the behavior of a process
Central Limit Theorem

34. In a regression - what does the coefficient of the intercept tell you
Stratify a particular defect type according to logical criteria
It looks to minimize the probability of a failure - or to minimize its effects
What the value of the dependent variable is when the independent variable is zero.
Fishbone - cause-and-effect diagram.

35. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Initiated before or at design concept finalization
Sampling for SPC is done real time.
Variable.
Outside.

36. What is the role of a black belt?
The secondary characteristics of a product; "bells and whistles."
No -- if it is not the same - it can only be worse!
Is what induces the failure
To manage the Six Sigma project.

37. Define aesthetic quality.
The House of Quality.
Upper control limit.
Pleasing to the senses.
Large enough to find two of the attribute - on average.

38. What is a Gage R&R?
Is the consequence of the failure.
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).
Speed - courtesy - competence - and ease of repair.
The gap between what is promised and what is delivered.

39. What type of risk is associated with Type 1 Error?
X-bar-bar
Represents the behavior of a process
Producer risk.
Concluding there has been an effect/change when there has not.

40. Test for constant variance
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
p-bar - the long-run percent defective.
The degree to which a product meets pre-established standards.
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.

41. FMEA
Lean (or JIT).
The US national quality award.
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
Used to create frequency distribution tally sheets

42. What is the role of a green belt?
Different types of defects are listed (used for Pareto chart)
To be a member of a Six Sigma project team.
The US national quality award.
The gap between what customers expect and the service they receive.

43. In the Service Quality Gap Model - what is Gap 5?
Kaoru Ishikawa.
To monitor a process when measurement by variables is used.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
The gap between what customers expect and the service they receive.

44. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Hold all input variables constant except one. Observe the response as you vary the single input.
Pleasing to the senses.
The Japanese national quality award.
Lower skill requirements - faster - less chance for error.

45. Pareto Analysis
Initiated before or at design concept finalization
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).
=sqrt(Σ(x-x-bar)^2)/(n-1))

46. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
Method developed by Ishikawa to graphically display the causes of any given problem
Actual drawings - layouts - maps - etc which show where a defect occurs
10 for Hazardous without warning 1 for none

47. The data points on an SPC p-chart of defective percent plot below the mean. Is this good or bad?

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48. One factor at a time (OFAT)
Outside.
Hold all input variables constant except one. Observe the response as you vary the single input.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
No -- if it is not the same - it can only be worse!

49. Cause and Effect Diagrams
A brainstorming tool that shows the connections between ideas.
Method developed by Ishikawa to graphically display the causes of any given problem
Prevention - appraisal - internal failure - external failure.
Fishbone - cause-and-effect diagram.

50. What is CTQ?
Fishbone - cause-and-effect diagram.
Critical to quality.
Conformance to specifications.
To monitor a process when measurement by variables is used.