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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. Process occurance ranking
Concluding there has been an effect/change when there has not.
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.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Pleasing to the senses.

2. What does DMAIC stand for?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Different types of defects are listed (used for Pareto chart)
Define - measure - analyze - improve - control.

3. Explain the difference between technical and functional service quality.
Technical quality is the "what" of the service; functional quality is the "how."
Is the consequence of the failure.
Represents the behavior of a process
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

4. In a Z table - what is Z?
Not necessarily.
F_alpha - df(tr) - df (error)
The number of standard deviations some value is from the mean.
10 for Hazardous without warning 1 for none

5. What is DPMO?
3.4 (assuming 1.5 sigma shift in the mean)
Attribute
A diagram that shows the relationships between activities in a project network.
Defects Per Million Opportunities

6. In a regression - what does R-square tell you?
Hold all input variables constant except one. Observe the response as you vary the single input.
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
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
5%

7. Regression
Is the way in which the failure is manifested.
Represents the behavior of a process
It looks to minimize the probability of a failure - or to minimize its effects
Lean (or JIT).

8. What is the Baldrige Award?
Financial - customer - internal process - innovation and learning.
99.73%
The US national quality award.
Variable.

9. PFMEA
3.4 (assuming 1.5 sigma shift in the mean)
Because the mean and standard deviation are independent of each other.
Before production starts
If the Response vs. Levels graph if the response lines are not parallel (crossing)

10. What is a Gage R&R?
Before production starts
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).
Concluding there has not been an effect/change when there has.
Shifts - Trends - Repeating patterns - Correlation with known events

11. What is the role of a master black belt?
To mentor/coach (and sometimes train) black belts.
The gap between what management thinks customers want and what customers really want.
Controlling quality at the source.
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

12. TWO-DIMENTIONAL SCATTER PLOT
Central Limit Theorem
95%
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

13. Daniel Test
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
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:
Used to create frequency distribution tally sheets
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

14. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Variable.
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.
Central Limit Theorem
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

15. What is CTQ?
Critical to quality.
The number of standard deviations some value is from the mean.
The gap between specifications and how service is performed.
The Japanese national quality award.

16. Non-random patterns (Run Charts)
10 if Almost impossible to detect
Linearity - normality - homoscedasticity - independence.
It's good -- but it's still out of control!
Shifts - Trends - Repeating patterns - Correlation with known events

17. If a three-stage process has 90% yields at each stage - what is the overall yield?
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.
0.9^3 or 72.9%
Large enough to find two of the attribute - on average.
No -- the variation also has to be random and "expected."

18. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Used to create frequency distribution tally sheets
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
68%
Mean time to failure.

19. What percentage of a normal distribution lies above the mean?
F_alpha - df(tr) - df (error)
A descending order-sorted bar chart with a cumulative percentage line.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
50%

20. Process check sheets
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Used to create frequency distribution tally sheets
To be a member of a Six Sigma project team.
Variable.

21. What does a project prioritization matrix do?
The gap between what management thinks customers want and the process specifications.
The cycle time required to meet demand.
Assigns scores to weighted criteria for each project under consideration.
Used to create frequency distribution tally sheets

22. List two components of prevention cost.
Central Limit Theorem
A diagram that shows the relationships between activities in a project network.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
F_alpha - df(tr) - df (error)

23. What is an affinity diagram?
A scatterplot.
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 brainstorming tool that shows the connections between ideas.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

24. Name the structure associated with Quality Function Deployment.
Technical quality is the "what" of the service; functional quality is the "how."
Method developed by Ishikawa to graphically display the causes of any given problem
The House of Quality.
Variable.

25. The data points on an SPC p-chart of defective percent plot below the mean. Is this good or bad?

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26. Complete this quality phrase: 'Fix the process - not the _____.'
It looks to minimize the probability of a failure - or to minimize its effects
An assertion or conjecture concerning one or more populations
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Blame.

27. List two appraisal costs.
Before production starts
The gap between what is promised and what is delivered.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
It's good -- but it's still out of control!

28. What are the Five Dimensions of Service Quality?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Reliability - Assurance - Responsiveness - Tangibles - Empathy
A tool that shows performance along key dimensions all at once.
False - because each machine will have different natural tolerances.

29. FMEA
It looks to minimize the probability of a failure - or to minimize its effects
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Look for the assignable cause of non-random variation.
It's good -- but it's still out of control!

30. One factor at a time (OFAT)
0.9^3 or 72.9%
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Outside.
Observed variation in response is caused by the input

31. What are the 5 Ss?
Sort - Set in Order - Shine - Standardize - Sustain
QFD
Walter A. Shewhart
A scatterplot.

32. What is muda
Conformance to specifications.
Causes that lead to a particular effect.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Waste.

33. List two components of external failure.
A tool that shows where there is waste in a process.
Observed variation in response is caused by the input
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Stratify a particular defect type according to logical criteria

34. What is the role of a black belt?
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)
68%
To manage the Six Sigma project.

35. A process is operating "in control." Does this mean the customer's requirements are met?
0.9^3 or 72.9%
Attribute
No -- only if the process is also capable.
The number of standard deviations some value is from the mean.

36. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
100%
The Japanese national quality award.
Mean time to failure.

37. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
The gap between what management thinks customers want and what customers really want.
Attribute
0.9^3 or 72.9%
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).

38. Defect check sheets
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
To monitor a process when measurement by attribute is used.
No -- the variation also has to be random and "expected."
Different types of defects are listed (used for Pareto chart)

39. Manual Test for Nomality
Kaoru Ishikawa.
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
Outside.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

40. What are the three main categories of assignable cause?
100%
Scrap - rework - retest - downtime - yield losses - disposition costs.
Different types of defects are listed (used for Pareto chart)
Workers - machines - materials.

41. If you have calculated a Cpk - should you also calculate a Cp?
Concluding there has not been an effect/change when there has.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Consumer risk.
Critical to quality.

42. Risk Priority Number RPN
A tool that shows where there is waste in a process.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
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.
Lean is waste reduction - Six Sigma is variation reduction.

43. What is the center line of a p-chart?
p-bar - the long-run percent defective.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Reliability - Assurance - Responsiveness - Tangibles - Empathy

44. What is the difference between Lean and Six Sigma?
Critical to quality.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
What the value of the dependent variable is when the independent variable is zero.
Lean is waste reduction - Six Sigma is variation reduction.

45. In the Service Quality Gap Model - what is Gap 2?
To monitor a process when measurement by attribute is used.
Initiated before or at design concept finalization
The gap between what management thinks customers want and the process specifications.
= 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

46. What is the formula for the standard deviation of a proportion?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
The ratio of outputs to inputs; 1-scrap.
=sqrt((p*(1-p)/n)
99.73%

47. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
To monitor a process when measurement by attribute is used.
95%
Deming.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

48. In Juran's Cost of Quality model - which categories of costs balance which other categories?
=sqrt(Σ(x-x-bar)^2)/(n-1))
Prevention and appraisal costs are balanced against internal and external failure.
Technical quality is the "what" of the service; functional quality is the "how."
The ratio of outputs to inputs; 1-scrap.

49. What happens to control limits on an SPC chart when sample size is increased?
They move closer to the center line.
The target number of standard deviations from the mean for specifications.
Fishbone - cause-and-effect diagram.
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).

50. Your production process meets customer specifications. Is your process in control?
Not necessarily.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
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