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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. How does Juran define quality?
Fitness for use.
A brainstorming tool that shows the connections between ideas.
Supplier - input - process - output - customer.
To monitor a process when measurement by attribute is used.

2. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
5%
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

3. What is an affinity diagram?
A brainstorming tool that shows the connections between ideas.
Kaoru Ishikawa.
To mentor/coach (and sometimes train) black belts.
F_alpha - df(tr) - df (error)

4. Advantages of DOE
Producer risk.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Shifts - Trends - Repeating patterns - Correlation with known events
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

5. Define aesthetic quality.
The Japanese national quality award.
Pleasing to the senses.
To monitor a process when measurement by attribute is used.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

6. What is the Deming Prize?
Controlling quality at the source.
Fitness for use.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The Japanese national quality award.

7. PFMEA
Before production starts
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
A tool that shows performance along key dimensions all at once.
The gap between what is promised and what is delivered.

8. What is the Baldrige Award?
Variable.
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 US national quality award.
A brainstorming tool that shows the connections between ideas.

9. What type of risk is associated with Type II Error?
To do a capability study for a non-centered process.
Consumer risk.
The gap between what management thinks customers want and the process specifications.
Fewer good units to sell - increased variable cost/unit.

10. Detection Criteria Ranking
Because the mean and standard deviation are independent of each other.
To do a capability study for a non-centered process.
10 if Almost impossible to detect
Through producer/consumer negotiation.

11. Design of Experiments (DOE) approach
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Speed - courtesy - competence - and ease of repair.
The gap between what customers expect and the service they receive.
It's good -- but it's still out of control!

12. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
95%
10 for Hazardous without warning 1 for none
It looks to minimize the probability of a failure - or to minimize its effects
The number of standard deviations some value is from the mean.

13. What is a Gage R&R?
To obtain a certain desirable outcome from the process
A random variable that summarizes the information from the sample(s).
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 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).

14. One factor at a time (OFAT)
To do a capability study for a non-centered process.
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
Observed variation in response is caused by the input

15. Daniel Test
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:
X-bar-bar
Studying firms with the best performance in a particular area.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

16. What is Jidoka?
The ability of a process to consistently meet customer specifications.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Controlling quality at the source.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

17. Based on what principal can we use the normal distribution assumptions for SPC?
A time series plot.
Shifts - Trends - Repeating patterns - Correlation with known events
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Central Limit Theorem

18. How are LQL and AQL determined in an acceptance sampling plan?
Critical to quality.
Through producer/consumer negotiation.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
=sqrt((p*(1-p)/n)

19. What is CTQ?
95%
Critical to quality.
Fitness for use.
The gap between specifications and how service is performed.

20. Defect location check sheets
Failure Modes and Effects Analysis
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Actual drawings - layouts - maps - etc which show where a defect occurs
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

21. What happens to control limits on an SPC chart when sample size is increased?
They move closer to the center line.
Lower skill requirements - faster - less chance for error.
The ability of a process to consistently meet customer specifications.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

22. What is Value Stream Mapping?
Is the consequence of the failure.
Rapid improvement process.
Technical quality is the "what" of the service; functional quality is the "how."
A tool that shows where there is waste in a process.

23. One factor at a time (OFAT)
5%
The manager in charge of a process being improved in a Six Sigma project.
Controlling quality at the source.
Hold all input variables constant except one. Observe the response as you vary the single input.

24. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Prevention and appraisal costs are balanced against internal and external failure.
Attribute
100%
Used to create frequency distribution tally sheets

25. Process check sheets
Used to create frequency distribution tally sheets
The gap between what is promised and what is delivered.
Lower control limit.
3.4 (assuming 1.5 sigma shift in the mean)

26. What percentage of a normal distribution lies above the mean?
The ratio of outputs to inputs; 1-scrap.
Speed - courtesy - competence - and ease of repair.
50%
Taguchi

27. With Six Sigma capability - how many defects per million opportunities would you see?
Define - measure - analyze - design - verify.
50%
It's good -- but it's still out of control!
3.4 (assuming 1.5 sigma shift in the mean)

28. What does Crosby say about benchmarking?
The House of Quality.
The ratio of outputs to inputs; 1-scrap.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Speed - courtesy - competence - and ease of repair.

29. What is Little's Law?
= yij - y(bar)i --> value minus sum of that treatment (of row)
Inventory = throughput x flow time.
To be a member of a Six Sigma project team.
Is what induces the failure

30. Residual
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
A tool that shows performance along key dimensions all at once.
A time series plot.
Define - measure - analyze - design - verify.

31. 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.
The ratio of outputs to inputs; 1-scrap.
Mistake-proofing.

32. What are two other names for an Ishikawa diagram?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Fishbone - cause-and-effect diagram.
Shows the temporal flow of activities in a project network.
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:

33. Effect ranking (Severity of the Defect)
Workers - machines - materials.
No -- the variation also has to be random and "expected."
10 for Hazardous without warning 1 for none
A descending order-sorted bar chart with a cumulative percentage line.

34. Your production process meets customer specifications. Is your process in control?
Not necessarily.
Can't tell without a Range chart.
F_alpha - df(tr) - df (error)
Fishbone - cause-and-effect diagram.

35. The Test Statistic (TS)
Lean (or JIT).
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
A random variable that summarizes the information from the sample(s).
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

36. What is DMADV?
Prevention and appraisal costs are balanced against internal and external failure.
Define - measure - analyze - design - verify.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

37. What are the four categories of costs in Juran's framework?
Consumer risk.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
The ratio of outputs to inputs; 1-scrap.
Prevention - appraisal - internal failure - external failure.

38. Stratified defect check sheets
Organize ideas into meaningful categories by recognizing their underlying similarity
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
To monitor a process when measurement by attribute is used.
Stratify a particular defect type according to logical criteria

39. In the Service Quality Gap Model - what is Gap 5?
Can't tell without a Range chart.
Studying firms with the best performance in a particular area.
The gap between what customers expect and the service they receive.
Mistake-proofing.

40. When yields decrease - what are the two effects on contribution?
Fewer good units to sell - increased variable cost/unit.
Organize ideas into meaningful categories by recognizing their underlying similarity
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Causes that lead to a particular effect.

41. What does a project prioritization matrix do?
Assigns scores to weighted criteria for each project under consideration.
The gap between specifications and how service is performed.
To do a capability study for a non-centered process.
Waste.

42. Which type of SPC measurement is more precise - variable or attribute?
Variable.
Concluding there has been an effect/change when there has not.
A tool that shows where there is waste in a process.
The gap between specifications and how service is performed.

43. What are the three main categories of assignable cause?
Workers - machines - materials.
The degree to which a product meets pre-established standards.
Sampling for SPC is done real time.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

44. Histogram by Hand
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Variable.
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
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).

45. ANOVA

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46. What is a CAVE man?
5%
Someone who is consistently against virtually everything.
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.

47. Define perceived quality (Garvin's framework).
Supplier - input - process - output - customer.
A diagram that shows the relationships between activities in a project network.
Brand image.
Linearity - normality - homoscedasticity - independence.

48. What is a spaghetti diagram?
Pleasing to the senses.
A tool that shows the physical flows through a space.
The degree to which a product meets pre-established standards.
Mean time to replacement.

49. Explain the difference between technical and functional service quality.
0.9^3 or 72.9%
Technical quality is the "what" of the service; functional quality is the "how."
Inventory = throughput x flow time.
Speed - courtesy - competence - and ease of repair.

50. In the Service Quality Gap Model - what is Gap 2?
= yij - y(bar)i --> value minus sum of that treatment (of row)
Controlling quality at the source.
Blame.
The gap between what management thinks customers want and the process specifications.