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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 quality guru emphasizes management as a system?
68%
Waste.
To be a member of a Six Sigma project team.
Deming.

2. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Through producer/consumer negotiation.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

3. What does the abbreviation LCL stand for?
Lower control limit.
A tool that shows where there is waste in a process.
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
Concluding there has been an effect/change when there has not.

4. Daniel Test
Scrap - rework - retest - downtime - yield losses - disposition costs.
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:
The House of Quality.
A tool that shows performance along key dimensions all at once.

5. What is the formula for the standard deviation of a proportion?
Attribute
Consumer risk.
=sqrt((p*(1-p)/n)
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

6. With Six Sigma capability - how many defects per million opportunities would you see?
3.4 (assuming 1.5 sigma shift in the mean)
A time series plot.
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
A descending order-sorted bar chart with a cumulative percentage line.

7. Process check sheets
Scrap - rework - retest - downtime - yield losses - disposition costs.
Workers - machines - materials.
Mean time to replacement.
Used to create frequency distribution tally sheets

8. Uses of regression - Control
Central Limit Theorem
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
If the Response vs. Levels graph if the response lines are not parallel (crossing)
To obtain a certain desirable outcome from the process

9. What is a histogram?
Kaoru Ishikawa.
Is what induces the failure
Fishbone - cause-and-effect diagram.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

10. What happens to control limits on an SPC chart when sample size is increased?
A diagram that shows the relationships between activities in a project network.
They move closer to the center line.
0.9^3 or 72.9%
Someone who is consistently against virtually everything.

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
Brand image.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
100%

12. In a Z table - what is Z?
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.
Outside.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The number of standard deviations some value is from the mean.

13. If a Cp shows that a process is not capable - should you calculate Cpk?
To manage the Six Sigma project.
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.
No -- if it is not the same - it can only be worse!
Represents the behavior of a process

14. Define yield.
Producer risk.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The ratio of outputs to inputs; 1-scrap.
A tool that shows performance along key dimensions all at once.

15. Manual Test for Nomality
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Prevention and appraisal costs are balanced against internal and external failure.
Variable.

16. DOE
Large enough to find two of the attribute - on average.
QFD
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
The ratio of outputs to inputs; 1-scrap.

17. What size should samples be for attribute SPC?
Large enough to find two of the attribute - on average.
Kaoru Ishikawa.
Is what induces the failure
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

18. Define aesthetic quality.
Defects Per Million Opportunities
Pleasing to the senses.
A diagram that shows the relationships between activities in a project network.
A tool that shows the physical flows through a space.

19. Who first studied randomness in industrial processes
Lean is waste reduction - Six Sigma is variation reduction.
The degree to which a product meets pre-established standards.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Walter A. Shewhart

20. What is an affinity diagram?
To be a member of a Six Sigma project team.
A brainstorming tool that shows the connections between ideas.
100%
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

21. Stratified defect check sheets
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Lean is waste reduction - Six Sigma is variation reduction.
Stratify a particular defect type according to logical criteria

22. PFMEA
Shows the temporal flow of activities in a project network.
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).
Before production starts
The gap between what is promised and what is delivered.

23. What is a network diagram?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Observed variation in response is caused by the input
A diagram that shows the relationships between activities in a project network.
Lower control limit.

24. Uses of regression
Linearity - normality - homoscedasticity - independence.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Lean is waste reduction - Six Sigma is variation reduction.
Sort - Set in Order - Shine - Standardize - Sustain

25. What is the role of a green belt?
To be a member of a Six Sigma project team.
10 for Hazardous without warning 1 for none
Sort - Set in Order - Shine - Standardize - Sustain
X-bar-bar

26. What are the 5 Ss?
Sort - Set in Order - Shine - Standardize - Sustain
The House of Quality.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Look for the assignable cause of non-random variation.

27. Disadvantages of DOE

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28. Design of Experiments (DOE) approach
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Large enough to find two of the attribute - on average.
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

29. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Lower skill requirements - faster - less chance for error.
The manager in charge of a process being improved in a Six Sigma project.
Prevention and appraisal costs are balanced against internal and external failure.
5%

30. 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.
Because the mean and standard deviation are independent of each other.
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
Lower control limit.

31. What is Jidoka?
Represents the behavior of a process
The gap between what management thinks customers want and the process specifications.
Controlling quality at the source.
Concluding there has not been an effect/change when there has.

32. What is the Baldrige Award?
A descending order-sorted bar chart with a cumulative percentage line.
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.
The US national quality award.
It looks to minimize the probability of a failure - or to minimize its effects

33. What is a run chart?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Prevention and appraisal costs are balanced against internal and external failure.
The cycle time required to meet demand.
A time series plot.

34. If you have calculated a Cpk - should you also calculate a Cp?
Shows the temporal flow of activities in a project network.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Attribute
10 for Hazardous without warning 1 for none

35. What is Value Stream Mapping?
Upper control limit.
A tool that shows where there is waste in a process.
Shifts - Trends - Repeating patterns - Correlation with known events
False - because each machine will have different natural tolerances.

36. What does the abbreviation UCL stand for?
Used to create frequency distribution tally sheets
Upper control limit.
0.9^3 or 72.9%
Concluding there has been an effect/change when there has not.

37. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
A tool that shows the physical flows through a space.
100%
Walter A. Shewhart

38. In the Service Quality Gap Model - what is Gap 2?
The Japanese national quality award.
Fitness for use.
The gap between what management thinks customers want and the process specifications.
Causes that lead to a particular effect.

39. Define benchmarking.
Conformance to specifications.
Studying firms with the best performance in a particular area.
To obtain a certain desirable outcome from the process
=sqrt((p*(1-p)/n)

40. To what does the Six in Six Sigma relate?
Lower skill requirements - faster - less chance for error.
Variable.
The target number of standard deviations from the mean for specifications.
95%

41. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
To do a capability study for a non-centered process.
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
The gap between specifications and how service is performed.
Variable.

42. What is the center line of a p-chart?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Stratify a particular defect type according to logical criteria
p-bar - the long-run percent defective.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

43. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Stratify a particular defect type according to logical criteria
The ability of a process to consistently meet customer specifications.
5%
Scrap - rework - retest - downtime - yield losses - disposition costs.

44. What is Kaizen?
Assigns scores to weighted criteria for each project under consideration.
Rapid improvement process.
A scatterplot.
Failure Modes and Effects Analysis

45. List Garvin's eight dimensions of product quality.
To manage the Six Sigma project.
Large enough to find two of the attribute - on average.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
If the Response vs. Levels graph if the response lines are not parallel (crossing)

46. How does Juran define 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).
= yij - y(bar)i --> value minus sum of that treatment (of row)
Fractional factorial designs (orthogonal arrays)
Fitness for use.

47. F value
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).
= yij - y(bar)i --> value minus sum of that treatment (of row)
0.9^3 or 72.9%
F_alpha - df(tr) - df (error)

48. If a three-stage process has 90% yields at each stage - what is the overall yield?
Organize ideas into meaningful categories by recognizing their underlying similarity
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
0.9^3 or 72.9%
The cycle time required to meet demand.

49. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
3.4 (assuming 1.5 sigma shift in the mean)
Shifts - Trends - Repeating patterns - Correlation with known events
Before production starts
Lean (or JIT).

50. List two components of external failure.
Actual drawings - layouts - maps - etc which show where a defect occurs
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
An assertion or conjecture concerning one or more populations
The gap between what management thinks customers want and the process specifications.