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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 is a dashboard?
= yij - y(bar)i --> value minus sum of that treatment (of row)
A tool that shows performance along key dimensions all at once.
Mistake-proofing.
Lean (or JIT).

2. When is Cpk used?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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
Assigns scores to weighted criteria for each project under consideration.
To do a capability study for a non-centered process.

3. Uses of regression - Control
To monitor a process when measurement by attribute is used.
To obtain a certain desirable outcome from the process
Controlling quality at the source.
Speed - courtesy - competence - and ease of repair.

4. Name the structure associated with Quality Function Deployment.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Critical to quality.
Blame.
The House of Quality.

5. What is written on the "spines" of a fishbone diagram?
Supplier - input - process - output - customer.
Large enough to find two of the attribute - on average.
It looks to minimize the probability of a failure - or to minimize its effects
Causes that lead to a particular effect.

6. In a regression - what does the coefficient of the intercept tell you
What the value of the dependent variable is when the independent variable is zero.
5%
Fractional factorial designs (orthogonal arrays)
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

7. What is FMEA?
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).
Failure Modes and Effects Analysis
Look for the assignable cause of non-random variation.
To mentor/coach (and sometimes train) black belts.

8. Who is a process owner?
The secondary characteristics of a product; "bells and whistles."
Shows the temporal flow of activities in a project network.
The manager in charge of a process being improved in a Six Sigma project.
QFD

9. Creating a Run Chart
A tool that shows the physical flows through a space.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Shows the temporal flow of activities in a project network.
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

10. Define perceived quality (Garvin's framework).
Different types of defects are listed (used for Pareto chart)
Kaoru Ishikawa.
Brand image.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

11. What are two other names for an Ishikawa diagram?
Fishbone - cause-and-effect diagram.
= 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
99.73%

12. You have been plotting sample means on an x-bar chart and all points indicate normal - expected variation. Is the process in control?

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13. Histogram by Hand
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
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 House of Quality.
Defects Per Million Opportunities

14. What is the formula for the standard deviation of a proportion?
The target number of standard deviations from the mean for specifications.
Defects Per Million Opportunities
=sqrt((p*(1-p)/n)
It looks to minimize the probability of a failure - or to minimize its effects

15. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Mean time to replacement.
The secondary characteristics of a product; "bells and whistles."
Outside.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

16. The Test Statistic (TS)
Controlling quality at the source.
A random variable that summarizes the information from the sample(s).
To manage the Six Sigma project.
Causes that lead to a particular effect.

17. What is poka yoke?
=sqrt((p*(1-p)/n)
To monitor a process when measurement by variables is used.
Observed variation in response is caused by the input
Mistake-proofing.

18. Based on what principal can we use the normal distribution assumptions for SPC?
To monitor a process when measurement by attribute is used.
Consumer risk.
Central Limit Theorem
Producer risk.

19. What quality guru emphasizes management as a system?
The degree to which a product meets pre-established standards.
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).
Deming.
Actual drawings - layouts - maps - etc which show where a defect occurs

20. Failure effect
Through producer/consumer negotiation.
Because the mean and standard deviation are independent of each other.
Is the consequence of the failure.
Failure Modes and Effects Analysis

21. Define benchmarking.
Studying firms with the best performance in a particular area.
A descending order-sorted bar chart with a cumulative percentage line.
False - because each machine will have different natural tolerances.
Fitness for use.

22. What is DPMO?
Defects Per Million Opportunities
No -- the variation also has to be random and "expected."
Different types of defects are listed (used for Pareto chart)
Observed variation in response is caused by the input

23. Affinity Diagrams
The gap between specifications and how service is performed.
The House of Quality.
Observed variation in response is caused by the input
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

24. What is a Pareto chart?
3.4 (assuming 1.5 sigma shift in the mean)
To do a capability study for a non-centered process.
Not necessarily.
A descending order-sorted bar chart with a cumulative percentage line.

25. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Variable.
Before production starts

26. Residual
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
A descending order-sorted bar chart with a cumulative percentage line.
Define - measure - analyze - improve - control.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

27. Which quality guru developed the concept of loss to society?
p-bar - the long-run percent defective.
No -- only if the process is also capable.
Taguchi
= 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

28. What is the 5S model?
A diagram that shows the relationships between activities in a project network.
5%
The primary operating characteristics of a product.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

29. Define performance quality.
The gap between specifications and how service is performed.
The primary operating characteristics of a product.
Someone who is consistently against virtually everything.
Define - measure - analyze - improve - control.

30. In a regression - what does R-square tell you?
Through producer/consumer negotiation.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Outside.
The number of standard deviations some value is from the mean.

31. What are the Five Dimensions of Service Quality?
A brainstorming tool that shows the connections between ideas.
Consumer risk.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Lean is waste reduction - Six Sigma is variation reduction.

32. What is Type 1 Error?
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
5%
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Concluding there has been an effect/change when there has not.

33. List two components of internal failure.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Represents the behavior of a process
50%
Scrap - rework - retest - downtime - yield losses - disposition costs.

34. For what is an x-bar chart used?
Stratify a particular defect type according to logical criteria
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Mistake-proofing.
To monitor a process when measurement by variables is used.

35. Definition of Interaction
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Taguchi
Rapid improvement process.
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

36. Affinity Diagrams
Organize ideas into meaningful categories by recognizing their underlying similarity
= 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
Blame.
Pleasing to the senses.

37. What is CTQ?
Sort - Set in Order - Shine - Standardize - Sustain
Critical to quality.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
The Japanese national quality award.

38. Defect check sheets
Lower control limit.
Different types of defects are listed (used for Pareto chart)
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
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

39. Your production process meets customer specifications. Is your process in control?
Define - measure - analyze - improve - control.
10 for Hazardous without warning 1 for none
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Not necessarily.

40. Simple Regression Analysis (one factor regression model)
Assigns scores to weighted criteria for each project under consideration.
Causes that lead to a particular effect.
Consumer risk.
= 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

41. Daniel Test
=sqrt(Σ(x-x-bar)^2)/(n-1))
Sort - Set in Order - Shine - Standardize - Sustain
Prevention and appraisal costs are balanced against internal and external failure.
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:

42. FMEA
The secondary characteristics of a product; "bells and whistles."
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
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
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

43. Uses of regression
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
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
Taguchi

44. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
95%
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Lean is waste reduction - Six Sigma is variation reduction.
Lower skill requirements - faster - less chance for error.

45. What graphical tool is used to show the relationship between two numerical variables?
Concluding there has been an effect/change when there has not.
A scatterplot.
Kaoru Ishikawa.
Because the mean and standard deviation are independent of each other.

46. What is DMADV?
Define - measure - analyze - design - verify.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Speed - courtesy - competence - and ease of repair.
They move closer to the center line.

47. How does Juran define quality?
The degree to which a product meets pre-established standards.
Observed variation in response is caused by the input
Fitness for use.
Lean (or JIT).

48. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
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
95%
The gap between what management thinks customers want and what customers really want.

49. Failure Mode
Is the way in which the failure is manifested.
99.73%
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Causes that lead to a particular effect.

50. What is the role of a green belt?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
No -- if it is not the same - it can only be worse!
To be a member of a Six Sigma project team.
A scatterplot.