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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. Uses of regression - Control
To obtain a certain desirable outcome from the process
Shifts - Trends - Repeating patterns - Correlation with known events
Mean time to replacement.
Actual drawings - layouts - maps - etc which show where a defect occurs

2. If a Cp shows that a process is not capable - should you calculate Cpk?
Lower skill requirements - faster - less chance for error.
The cycle time required to meet demand.
No -- if it is not the same - it can only be worse!
Before production starts

3. What is the role of a green belt?
No -- the variation also has to be random and "expected."
X-bar-bar
A brainstorming tool that shows the connections between ideas.
To be a member of a Six Sigma project team.

4. What is Little's Law?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Inventory = throughput x flow time.
10 if Almost impossible to detect
Upper control limit.

5. Pareto Analysis
Pleasing to the senses.
Organize ideas into meaningful categories by recognizing their underlying similarity
Fishbone - cause-and-effect diagram.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

6. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
No -- only if the process is also capable.
5%
Actual drawings - layouts - maps - etc which show where a defect occurs
Prevention and appraisal costs are balanced against internal and external failure.

7. In a regression - what does R-square tell you?
Blame.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Walter A. Shewhart
10 for Hazardous without warning 1 for none

8. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
No -- only if the process is also capable.
Lower skill requirements - faster - less chance for error.
Shows the temporal flow of activities in a project network.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

9. Process check sheets
Used to create frequency distribution tally sheets
The degree to which a product meets pre-established standards.
No -- the variation also has to be random and "expected."
A descending order-sorted bar chart with a cumulative percentage line.

10. Explain the difference between technical and functional service quality.
Kaoru Ishikawa.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
To be a member of a Six Sigma project team.
Technical quality is the "what" of the service; functional quality is the "how."

11. Test for constant variance
Before production starts
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.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
The manager in charge of a process being improved in a Six Sigma project.

12. What is the 5S model?
Is the consequence of the failure.
Fewer good units to sell - increased variable cost/unit.
No -- the variation also has to be random and "expected."
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

13. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
They move closer to the center line.
95%
Is the way in which the failure is manifested.
Walter A. Shewhart

14. What is FMEA?
A time series plot.
An assertion or conjecture concerning one or more populations
Failure Modes and Effects Analysis
To mentor/coach (and sometimes train) black belts.

15. What are the Five Dimensions of Service Quality?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Linearity - normality - homoscedasticity - independence.
Concluding there has not been an effect/change when there has.
Different types of defects are listed (used for Pareto chart)

16. Define benchmarking.
Studying firms with the best performance in a particular area.
Lean (or JIT).
The manager in charge of a process being improved in a Six Sigma project.
Different types of defects are listed (used for Pareto chart)

17. What type of risk is associated with Type 1 Error?
The ratio of outputs to inputs; 1-scrap.
Consumer risk.
Producer risk.
Observed variation in response is caused by the input

18. Affinity Diagrams
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The gap between what management thinks customers want and what customers really want.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Used to create frequency distribution tally sheets

19. Regression
A tool that shows the physical flows through a space.
Represents the behavior of a process
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
X-bar-bar

20. List two components of external failure.
Attribute
Fishbone - cause-and-effect diagram.
Lean is waste reduction - Six Sigma is variation reduction.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

21. Process occurance ranking
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Studying firms with the best performance in a particular area.
Pleasing to the senses.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

22. With Six Sigma capability - how many defects per million opportunities would you see?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
3.4 (assuming 1.5 sigma shift in the mean)
Taguchi
Different types of defects are listed (used for Pareto chart)

23. What quality guru emphasizes management as a system?
It's good -- but it's still out of control!
Shows the temporal flow of activities in a project network.
Inventory = throughput x flow time.
Deming.

24. What is Type 1 Error?
The manager in charge of a process being improved in a Six Sigma project.
It looks to minimize the probability of a failure - or to minimize its effects
5%
Concluding there has been an effect/change when there has not.

25. In the Service Quality Gap Model - what is Gap 1?
Blame.
Fitness for use.
Taguchi
The gap between what management thinks customers want and what customers really want.

26. If you have calculated a Cpk - should you also calculate a Cp?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
QFD
Fewer good units to sell - increased variable cost/unit.
Inventory = throughput x flow time.

27. What does SIPOC stand for?
68%
The secondary characteristics of a product; "bells and whistles."
The gap between what management thinks customers want and what customers really want.
Supplier - input - process - output - customer.

28. Define conformance quality.
Represents the behavior of a process
The ratio of outputs to inputs; 1-scrap.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The degree to which a product meets pre-established standards.

29. What are two other names for an Ishikawa diagram?
Can't tell without a Range chart.
Hold all input variables constant except one. Observe the response as you vary the single input.
Causes that lead to a particular effect.
Fishbone - cause-and-effect diagram.

30. Cause and Effect Diagrams
10 if Almost impossible to detect
False - because each machine will have different natural tolerances.
Someone who is consistently against virtually everything.
Method developed by Ishikawa to graphically display the causes of any given problem

31. What does Crosby say about benchmarking?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Concluding there has been an effect/change when there has not.
Linearity - normality - homoscedasticity - independence.
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:

32. What is poka yoke?
=sqrt(Σ(x-x-bar)^2)/(n-1))
Mistake-proofing.
X-bar-bar
A scatterplot.

33. Creating a Run Chart
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Deming.
Causes that lead to a particular effect.
Large enough to find two of the attribute - on average.

34. What does the abbreviation LCL stand for?
Fewer good units to sell - increased variable cost/unit.
Is what induces the failure
Attribute
Lower control limit.

35. What is the formula for the standard deviation of a proportion?
The gap between what management thinks customers want and what customers really want.
=sqrt((p*(1-p)/n)
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Consumer risk.

36. FMEA
It looks to minimize the probability of a failure - or to minimize its effects
Conformance to specifications.
To monitor a process when measurement by attribute is used.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

37. What is a dashboard?
False - because each machine will have different natural tolerances.
Deming.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
A tool that shows performance along key dimensions all at once.

38. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The degree to which a product meets pre-established standards.
0.9^3 or 72.9%
100%

39. ANOVA

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40. In a Z table - what is Z?
The degree to which a product meets pre-established standards.
The number of standard deviations some value is from the mean.
An assertion or conjecture concerning one or more populations
Attribute.

41. Failure Mode
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
The cycle time required to meet demand.
Is the way in which the failure is manifested.
Fishbone - cause-and-effect diagram.

42. What is Type II Error?
Concluding there has not been an effect/change when there has.
Technical quality is the "what" of the service; functional quality is the "how."
Rapid improvement process.
Scrap - rework - retest - downtime - yield losses - disposition costs.

43. Design of Experiments (DOE) approach
The secondary characteristics of a product; "bells and whistles."
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Someone who is consistently against virtually everything.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

44. What are the four regression assumptions?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Variable.
It's good -- but it's still out of control!
Linearity - normality - homoscedasticity - independence.

45. What are the four categories of costs in Juran's framework?
Prevention - appraisal - internal failure - external failure.
3.4 (assuming 1.5 sigma shift in the mean)
Method developed by Ishikawa to graphically display the causes of any given problem
The gap between what management thinks customers want and the process specifications.

46. List two components of internal failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
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
Central Limit Theorem
Represents the behavior of a process

47. Define product reliability.
Define - measure - analyze - design - verify.
Define - measure - analyze - improve - control.
3.4 (assuming 1.5 sigma shift in the mean)
Mean time to failure.

48. In the Service Quality Gap Model - what is Gap 4?
The gap between what is promised and what is delivered.
Prevention - appraisal - internal failure - external failure.
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
=sqrt((p*(1-p)/n)

49. What does DMAIC stand for?
Define - measure - analyze - improve - control.
0.9^3 or 72.9%
Waste.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

50. Complete this quality phrase: 'Fix the process - not the _____.'
Assigns scores to weighted criteria for each project under consideration.
Blame.
Scrap - rework - retest - downtime - yield losses - disposition costs.
The cycle time required to meet demand.