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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. List two components of external failure.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Financial - customer - internal process - innovation and learning.
Brand image.
Controlling quality at the source.

2. Who first studied randomness in industrial processes
Deming.
Walter A. Shewhart
= yij - y(bar)i --> value minus sum of that treatment (of row)
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. Cause and Effect Diagrams
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Pleasing to the senses.
Before production starts
Method developed by Ishikawa to graphically display the causes of any given problem

4. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
A tool that shows where there is waste in a process.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Supplier - input - process - output - customer.
No -- the variation also has to be random and "expected."

5. Who developed the fishbone diagram?
Sampling for SPC is done real time.
Kaoru Ishikawa.
Define - measure - analyze - improve - control.
F_alpha - df(tr) - df (error)

6. Simple Regression Analysis (one factor regression model)
To manage the Six Sigma project.
Actual drawings - layouts - maps - etc which show where a defect occurs
= 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
Through producer/consumer negotiation.

7. Presence of interaction effect
Represents the behavior of a process
Kaoru Ishikawa.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

8. What do you do when a process is out of control?
Sampling for SPC is done real time.
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
Look for the assignable cause of non-random variation.
95%

9. For what is a p-chart used?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
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 monitor a process when measurement by attribute is used.
Controlling quality at the source.

10. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
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
Attribute.
Actual drawings - layouts - maps - etc which show where a defect occurs
100%

11. What size should samples be for attribute SPC?
Studying firms with the best performance in a particular area.
Variable.
Large enough to find two of the attribute - on average.
Someone who is consistently against virtually everything.

12. Define performance quality.
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 target number of standard deviations from the mean for specifications.
Different types of defects are listed (used for Pareto chart)
The primary operating characteristics of a product.

13. What is Type 1 Error?
No -- the variation also has to be random and "expected."
Concluding there has been an effect/change when there has not.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Used to create frequency distribution tally sheets

14. In a Z table - what is Z?
F_alpha - df(tr) - df (error)
The US national quality award.
The number of standard deviations some value is from the mean.
The gap between what management thinks customers want and what customers really want.

15. What does SIPOC stand for?
Look for the assignable cause of non-random variation.
Supplier - input - process - output - customer.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The Japanese national quality award.

16. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
Fractional factorial designs (orthogonal arrays)
=sqrt((p*(1-p)/n)
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

17. What happens to control limits on an SPC chart when sample size is increased?
Define - measure - analyze - improve - control.
They move closer to the center line.
The gap between what is promised and what is delivered.
The secondary characteristics of a product; "bells and whistles."

18. What type of risk is associated with Type II Error?
Fishbone - cause-and-effect diagram.
Brand image.
Consumer risk.
Prevention and appraisal costs are balanced against internal and external failure.

19. What is a CAVE man?
Through producer/consumer negotiation.
Someone who is consistently against virtually everything.
=sqrt(Σ(x-x-bar)^2)/(n-1))
A time series plot.

20. What graphical tool is used to show the relationship between two numerical variables?
Fitness for use.
A scatterplot.
Taguchi
The ratio of outputs to inputs; 1-scrap.

21. What is Type II Error?
Concluding there has not been an effect/change when there has.
Causes that lead to a particular effect.
Lean is waste reduction - Six Sigma is variation reduction.
Not necessarily.

22. If a three-stage process has 90% yields at each stage - what is the overall yield?
A scatterplot.
Taguchi
Before production starts
0.9^3 or 72.9%

23. In the Service Quality Gap Model - what is Gap 3?
No -- only if the process is also capable.
The gap between specifications and how service is performed.
To obtain a certain desirable outcome from the process
A descending order-sorted bar chart with a cumulative percentage line.

24. In the Service Quality Gap Model - what is Gap 1?
The gap between what management thinks customers want and what customers really want.
Lower control limit.
Linearity - normality - homoscedasticity - independence.
The ratio of outputs to inputs; 1-scrap.

25. Define takt time.
The cycle time required to meet demand.
QFD
Lean is waste reduction - Six Sigma is variation reduction.
Define - measure - analyze - improve - control.

26. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Variable.
Outside.
Deming.
The ability of a process to consistently meet customer specifications.

27. Definition of Interaction
Conformance to specifications.
Mistake-proofing.
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
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

28. What are the 5 Ss?
Shows the temporal flow of activities in a project network.
Sort - Set in Order - Shine - Standardize - Sustain
The Japanese national quality award.
Deming.

29. Stratified defect check sheets
Waste.
Stratify a particular defect type according to logical criteria
Brand image.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

30. ANOVA

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31. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
Fractional factorial designs (orthogonal arrays)
The US national quality award.
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.

32. When yields decrease - what are the two effects on contribution?
Actual drawings - layouts - maps - etc which show where a defect occurs
Fewer good units to sell - increased variable cost/unit.
To do a capability study for a non-centered process.
Attribute

33. What does Crosby say about benchmarking?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Blame.
The primary operating characteristics of a product.
Used to create frequency distribution tally sheets

34. With Six Sigma capability - how many defects per million opportunities would you see?
3.4 (assuming 1.5 sigma shift in the mean)
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Failure Modes and Effects Analysis
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

35. What is Jidoka?
Upper control limit.
Workers - machines - materials.
Controlling quality at the source.
Fishbone - cause-and-effect diagram.

36. Manual Test for Nomality
The cycle time required to meet demand.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Producer risk.

37. What is muda
Blame.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Waste.
Mean time to replacement.

38. Define benchmarking.
Studying firms with the best performance in a particular area.
Lower control limit.
10 for Hazardous without warning 1 for none
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

39. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Technical quality is the "what" of the service; functional quality is the "how."
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
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
99.73%

40. What is FMEA?
50%
No -- the variation also has to be random and "expected."
Rapid improvement process.
Failure Modes and Effects Analysis

41. What is a spaghetti diagram?
The cycle time required to meet demand.
Prevention - appraisal - internal failure - external failure.
A tool that shows the physical flows through a space.
The gap between what is promised and what is delivered.

42. Define conformance quality.
The degree to which a product meets pre-established standards.
The manager in charge of a process being improved in a Six Sigma project.
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
To manage the Six Sigma project.

43. List two appraisal costs.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
It looks to minimize the probability of a failure - or to minimize its effects
Large enough to find two of the attribute - on average.
Central Limit Theorem

44. Uses of regression
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Linearity - normality - homoscedasticity - 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

45. Risk Priority Number RPN
The US national quality award.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Is what induces the failure
Lean (or JIT).

46. Pareto Analysis
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
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
Organize ideas into meaningful categories by recognizing their underlying similarity

47. In Juran's Cost of Quality model - which categories of costs balance which other categories?
To do a capability study for a non-centered process.
Producer risk.
Sort - Set in Order - Shine - Standardize - Sustain
Prevention and appraisal costs are balanced against internal and external failure.

48. What quality guru emphasizes management as a system?
Critical to quality.
Deming.
Method developed by Ishikawa to graphically display the causes of any given problem
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

49. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
Stratify a particular defect type according to logical criteria
The ratio of outputs to inputs; 1-scrap.
Attribute.

50. In the Service Quality Gap Model - what is Gap 2?
50%
99.73%
The gap between what management thinks customers want and the process specifications.
Scrap - rework - retest - downtime - yield losses - disposition costs.