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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 three main categories of assignable cause?
The number of standard deviations some value is from the mean.
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
Variable.
Workers - machines - materials.

2. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Variable.
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
Consumer risk.
Conformance to specifications.

3. What does the abbreviation LCL stand for?
Lower control limit.
10 for Hazardous without warning 1 for none
To monitor a process when measurement by attribute is used.
Initiated before or at design concept finalization

4. What is a spaghetti diagram?
Fractional factorial designs (orthogonal arrays)
Defects Per Million Opportunities
A tool that shows the physical flows through a space.
The ability of a process to consistently meet customer specifications.

5. 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?
A descending order-sorted bar chart with a cumulative percentage line.
A tool that shows the physical flows through a space.
False - because each machine will have different natural tolerances.
Walter A. Shewhart

6. When is Cpk used?
Linearity - normality - homoscedasticity - independence.
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.
3.4 (assuming 1.5 sigma shift in the mean)

7. Statistical Hypothesis
An assertion or conjecture concerning one or more populations
To do a capability study for a non-centered process.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Critical to quality.

8. Daniel Test
Look for the assignable cause of non-random variation.
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:
Because the mean and standard deviation are independent of each other.
Actual drawings - layouts - maps - etc which show where a defect occurs

9. If a Cp shows that a process is not capable - should you calculate Cpk?
No -- if it is not the same - it can only be worse!
Taguchi
p-bar - the long-run percent defective.
The manager in charge of a process being improved in a Six Sigma project.

10. Taguchi's experimental designs are of this type.
It looks to minimize the probability of a failure - or to minimize its effects
Fractional factorial designs (orthogonal arrays)
Supplier - input - process - output - customer.
Fitness for use.

11. Define takt time.
3.4 (assuming 1.5 sigma shift in the mean)
The cycle time required to meet demand.
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
Prevention and appraisal costs are balanced against internal and external failure.

12. What is the role of a black belt?
Observed variation in response is caused by the input
100%
Before production starts
To manage the Six Sigma project.

13. What do you do when a process is out of control?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Look for the assignable cause of non-random variation.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

14. In a regression - what does the standard error of the estimate tell you?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The primary operating characteristics of a product.
Shifts - Trends - Repeating patterns - Correlation with known events
A diagram that shows the relationships between activities in a project network.

15. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
The gap between specifications and how service is performed.
The gap between what management thinks customers want and what customers really want.
The gap between what management thinks customers want and the process specifications.
95%

16. What is FMEA?
Workers - machines - materials.
Brand image.
Failure Modes and Effects Analysis
Supplier - input - process - output - customer.

17. Advantages of DOE
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
Stratify a particular defect type according to logical criteria
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 monitor a process when measurement by attribute is used.

18. What is a Gantt chart?
Fractional factorial designs (orthogonal arrays)
Supplier - input - process - output - customer.
Shows the temporal flow of activities in a project network.
99.73%

19. What is written on the "spines" of a fishbone diagram?
Causes that lead to a particular effect.
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:
Lower skill requirements - faster - less chance for error.
p-bar - the long-run percent defective.

20. What graphical tool is used to show the relationship between two numerical variables?
The US national quality award.
To mentor/coach (and sometimes train) black belts.
A scatterplot.
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:

21. What is an affinity diagram?
A brainstorming tool that shows the connections between ideas.
Shifts - Trends - Repeating patterns - Correlation with known events
The primary operating characteristics of a product.
Fractional factorial designs (orthogonal arrays)

22. What is the role of a green belt?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
No -- the variation also has to be random and "expected."
An assertion or conjecture concerning one or more populations
To be a member of a Six Sigma project team.

23. Uses of regression - Control
The ability of a process to consistently meet customer specifications.
Look for the assignable cause of non-random variation.
Pleasing to the senses.
To obtain a certain desirable outcome from the process

24. Failure cause
Before production starts
p-bar - the long-run percent defective.
A brainstorming tool that shows the connections between ideas.
Is what induces the failure

25. Your production process meets customer specifications. Is your process in control?
Supplier - input - process - output - customer.
Not necessarily.
p-bar - the long-run percent defective.
Critical to quality.

26. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Sampling for SPC is done real time.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
95%
To monitor a process when measurement by variables is used.

27. ANOVA

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28. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
100%
No -- the variation also has to be random and "expected."
Controlling quality at the source.
A time series plot.

29. Detection Criteria Ranking
Not necessarily.
Lean is waste reduction - Six Sigma is variation reduction.
10 if Almost impossible to detect
The target number of standard deviations from the mean for specifications.

30. Explain the difference between technical and functional service quality.
Shifts - Trends - Repeating patterns - Correlation with known events
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
Technical quality is the "what" of the service; functional quality is the "how."
Conformance to specifications.

31. What is the Baldrige Award?
The ability of a process to consistently meet customer specifications.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
The US national quality award.

32. What is Jidoka?
Waste.
Technical quality is the "what" of the service; functional quality is the "how."
Controlling quality at the source.
The ratio of outputs to inputs; 1-scrap.

33. What does DMAIC stand for?
The House of Quality.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Define - measure - analyze - improve - control.
Taguchi

34. If a three-stage process has 90% yields at each stage - what is the overall yield?
Mean time to replacement.
The ratio of outputs to inputs; 1-scrap.
0.9^3 or 72.9%
Mistake-proofing.

35. What is Kaizen?
Central Limit Theorem
The House of Quality.
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
Rapid improvement process.

36. Design of Experiments (DOE) approach
X-bar-bar
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Shifts - Trends - Repeating patterns - Correlation with known events
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

37. What is a run chart?
Brand image.
Through producer/consumer negotiation.
A time series plot.
Fractional factorial designs (orthogonal arrays)

38. Failure effect
Workers - machines - materials.
Is the consequence of the failure.
The gap between specifications and how service is performed.
Central Limit Theorem

39. What percentage of a normal distribution lies above the mean?
50%
Shows the temporal flow of activities in a project network.
Attribute
The cycle time required to meet demand.

40. What is a dashboard?
The US national quality award.
A tool that shows performance along key dimensions all at once.
Concluding there has not been an effect/change when there has.
99.73%

41. What does the abbreviation UCL stand for?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Hold all input variables constant except one. Observe the response as you vary the single input.
A scatterplot.
Upper control limit.

42. FMEA
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
99.73%
It looks to minimize the probability of a failure - or to minimize its effects

43. How does Juran define quality?
Technical quality is the "what" of the service; functional quality is the "how."
Not necessarily.
Fitness for use.
Blame.

44. Cause and Effect Diagrams
Consumer risk.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Method developed by Ishikawa to graphically display the causes of any given problem
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).

45. The Test Statistic (TS)
They move closer to the center line.
99.73%
A random variable that summarizes the information from the sample(s).
Conformance to specifications.

46. In Juran's Cost of Quality model - which categories of costs balance which other categories?
99.73%
A tool that shows the physical flows through a space.
Conformance to specifications.
Prevention and appraisal costs are balanced against internal and external failure.

47. What is process capability?
Fewer good units to sell - increased variable cost/unit.
The ability of a process to consistently meet customer specifications.
To monitor a process when measurement by attribute is used.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

48. In the Service Quality Gap Model - what is Gap 1?
Deming.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The gap between what management thinks customers want and what customers really want.

49. Define product reliability.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Mean time to failure.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The primary operating characteristics of a product.

50. In the Service Quality Gap Model - what is Gap 3?
The gap between specifications and how service is performed.
Fitness for use.
Lower control limit.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value