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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. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
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
100%
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Defects Per Million Opportunities

2. Define benchmarking.
Taguchi
The primary operating characteristics of a product.
Studying firms with the best performance in a particular area.
Conformance to specifications.

3. Manual Test for Nomality
The ability of a process to consistently meet customer specifications.
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.
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:

4. What is muda
Consumer risk.
Waste.
The Japanese national quality award.
= 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

5. Disadvantages of DOE

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6. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
A tool that shows the physical flows through a space.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Initiated before or at design concept finalization
Lean (or JIT).

7. Stratified defect check sheets
Different types of defects are listed (used for Pareto chart)
Stratify a particular defect type according to logical criteria
Used to create frequency distribution tally sheets
Shifts - Trends - Repeating patterns - Correlation with known events

8. List two components of prevention cost.
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 chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Actual drawings - layouts - maps - etc which show where a defect occurs

9. What is DMADV?
Define - measure - analyze - design - verify.
No -- if it is not the same - it can only be worse!
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Actual drawings - layouts - maps - etc which show where a defect occurs

10. To what does the Six in Six Sigma relate?
The gap between specifications and how service is performed.
To monitor a process when measurement by variables is used.
The target number of standard deviations from the mean for specifications.
The cycle time required to meet demand.

11. List two components of internal failure.
A descending order-sorted bar chart with a cumulative percentage line.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Lean is waste reduction - Six Sigma is variation reduction.
Actual drawings - layouts - maps - etc which show where a defect occurs

12. In a regression - what does R-square tell you?
The gap between what customers expect and the service they receive.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Large enough to find two of the attribute - on average.

13. One factor at a time (OFAT)
Someone who is consistently against virtually everything.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
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
Hold all input variables constant except one. Observe the response as you vary the single input.

14. What are the four regression assumptions?
Attribute
Technical quality is the "what" of the service; functional quality is the "how."
Linearity - normality - homoscedasticity - independence.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

15. Affinity Diagrams
A tool that shows where there is waste in a process.
Organize ideas into meaningful categories by recognizing their underlying similarity
Financial - customer - internal process - innovation and learning.
Concluding there has not been an effect/change when there has.

16. Process check sheets
Used to create frequency distribution tally sheets
The US national quality award.
Lean (or JIT).
Assigns scores to weighted criteria for each project under consideration.

17. What is Type 1 Error?
Mean time to failure.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Concluding there has been an effect/change when there has not.
To obtain a certain desirable outcome from the process

18. In a Z table - what is Z?
Mean time to replacement.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Is the consequence of the failure.
The number of standard deviations some value is from the mean.

19. If you have calculated a Cpk - should you also calculate a Cp?
Financial - customer - internal process - innovation and learning.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Taguchi

20. How does Juran define quality?
Assigns scores to weighted criteria for each project under consideration.
Initiated before or at design concept finalization
No -- if it is not the same - it can only be worse!
Fitness for use.

21. A process is operating "in control." Does this mean the customer's requirements are met?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Taguchi
No -- only if the process is also capable.
They move closer to the center line.

22. What happens to control limits on an SPC chart when sample size is increased?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
They move closer to the center line.
Fewer good units to sell - increased variable cost/unit.

23. Uses of regression - Control
Inventory = throughput x flow time.
To obtain a certain desirable outcome from the process
No -- the variation also has to be random and "expected."
Lean is waste reduction - Six Sigma is variation reduction.

24. What is Value Stream Mapping?
Because the mean and standard deviation are independent of each other.
The Japanese national quality award.
An assertion or conjecture concerning one or more populations
A tool that shows where there is waste in a process.

25. Test for Independence
A brainstorming tool that shows the connections between ideas.
= 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
Attribute
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

26. Creating a Run Chart
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
F_alpha - df(tr) - df (error)
10 if Almost impossible to detect

27. What are the four categories of costs in Juran's framework?
68%
Can't tell without a Range chart.
Outside.
Prevention - appraisal - internal failure - external failure.

28. Defect location check sheets
Actual drawings - layouts - maps - etc which show where a defect occurs
A tool that shows where there is waste in a process.
Look for the assignable cause of non-random variation.
False - because each machine will have different natural tolerances.

29. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Conformance to specifications.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
The secondary characteristics of a product; "bells and whistles."
Through producer/consumer negotiation.

30. Definition of Interaction
= yij - y(bar)i --> value minus sum of that treatment (of row)
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

31. What is CTQ?
Can't tell without a Range chart.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Critical to quality.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

32. What is Kaizen?
The Japanese national quality award.
Rapid improvement process.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Attribute.

33. What are the 5 Ss?
The target number of standard deviations from the mean for specifications.
Sort - Set in Order - Shine - Standardize - Sustain
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
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

34. What does Crosby say about benchmarking?
Pleasing to the senses.
Lower control limit.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
X-bar-bar

35. What is a dashboard?
The cycle time required to meet demand.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
A brainstorming tool that shows the connections between ideas.
A tool that shows performance along key dimensions all at once.

36. List Garvin's eight dimensions of product quality.
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
Used to create frequency distribution tally sheets
To manage the Six Sigma project.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

37. Define features.
Is the consequence of the failure.
Pleasing to the senses.
The secondary characteristics of a product; "bells and whistles."
Lower skill requirements - faster - less chance for error.

38. Regression
Represents the behavior of a process
Fractional factorial designs (orthogonal arrays)
Not necessarily.
X-bar-bar

39. Effect ranking (Severity of the Defect)
Hold all input variables constant except one. Observe the response as you vary the single input.
= yij - y(bar)i --> value minus sum of that treatment (of row)
10 for Hazardous without warning 1 for none
Producer risk.

40. What is the Deming Prize?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Lower skill requirements - faster - less chance for error.
The Japanese national quality award.
Controlling quality at the source.

41. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Mean time to failure.
To manage the Six Sigma project.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
95%

42. What is the difference between Lean and Six Sigma?
Lean is waste reduction - Six Sigma is variation reduction.
Attribute.
The Japanese national quality award.
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

43. Residual
Prevention and appraisal costs are balanced against internal and external failure.
Consumer risk.
F_alpha - df(tr) - df (error)
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

44. List two components of external failure.
The US national quality award.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
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
0.9^3 or 72.9%

45. Test for constant variance
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Define - measure - analyze - improve - control.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
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.

46. If you can only collect categorical data - what type of SPC charting can you do?
Attribute.
Critical to quality.
Because the mean and standard deviation are independent of each other.
The target number of standard deviations from the mean for specifications.

47. Define yield.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Inventory = throughput x flow time.
QFD
The ratio of outputs to inputs; 1-scrap.

48. What is the 5S model?
No -- only if the process is also capable.
95%
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).
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

49. Define takt time.
5%
Lean (or JIT).
p-bar - the long-run percent defective.
The cycle time required to meet demand.

50. In a regression - what does the p value of F tell you?
The primary operating characteristics of a product.
No -- the variation also has to be random and "expected."
Mean time to failure.
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).