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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 the role of a master black belt?
Sort - Set in Order - Shine - Standardize - Sustain
To mentor/coach (and sometimes train) black belts.
Assigns scores to weighted criteria for each project under consideration.
Fractional factorial designs (orthogonal arrays)

2. List two appraisal costs.
Before production starts
Define - measure - analyze - improve - control.
100%
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

3. Process check sheets
Concluding there has been an effect/change when there has not.
Not necessarily.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Used to create frequency distribution tally sheets

4. What is the 5S model?
False - because each machine will have different natural tolerances.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
The cycle time required to meet demand.

5. Detection Criteria Ranking
To do a capability study for a non-centered process.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
10 if Almost impossible to detect
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

6. In a regression - what does the p value of F tell you?
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).
QFD
= yij - y(bar)i --> value minus sum of that treatment (of row)
= 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

7. What is Kaizen?
Rapid improvement process.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The gap between what is promised and what is delivered.
Pleasing to the senses.

8. What are the Five Dimensions of Service Quality?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Deming.
68%
Reliability - Assurance - Responsiveness - Tangibles - Empathy

9. What is a histogram?
Scrap - rework - retest - downtime - yield losses - disposition costs.
Waste.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Someone who is consistently against virtually everything.

10. Regression
10 if Almost impossible to detect
Rapid improvement process.
The cycle time required to meet demand.
Represents the behavior of a process

11. Define serviceability.
Speed - courtesy - competence - and ease of repair.
Sampling for SPC is done real time.
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).
Financial - customer - internal process - innovation and learning.

12. What is FMEA?
A diagram that shows the relationships between activities in a project network.
Speed - courtesy - competence - and ease of repair.
Failure Modes and Effects Analysis
= yij - y(bar)i --> value minus sum of that treatment (of row)

13. What is a CAVE man?
Fishbone - cause-and-effect diagram.
To manage the Six Sigma project.
Someone who is consistently against virtually everything.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

14. Presence of interaction effect
Waste.
To mentor/coach (and sometimes train) black belts.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Fewer good units to sell - increased variable cost/unit.

15. What does the abbreviation UCL stand for?
The secondary characteristics of a product; "bells and whistles."
False - because each machine will have different natural tolerances.
A descending order-sorted bar chart with a cumulative percentage line.
Upper control limit.

16. What graphical tool is used to show the relationship between two numerical variables?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Linearity - normality - homoscedasticity - independence.
Lower skill requirements - faster - less chance for error.
A scatterplot.

17. What is DPMO?
Technical quality is the "what" of the service; functional quality is the "how."
Defects Per Million Opportunities
99.73%
Inventory = throughput x flow time.

18. For what is an x-bar chart used?
Observed variation in response is caused by the input
A tool that shows performance along key dimensions all at once.
Look for the assignable cause of non-random variation.
To monitor a process when measurement by variables is used.

19. To what does the Six in Six Sigma relate?
=sqrt((p*(1-p)/n)
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
A descending order-sorted bar chart with a cumulative percentage line.
The target number of standard deviations from the mean for specifications.

20. Define conformance quality.
Walter A. Shewhart
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
The degree to which a product meets pre-established standards.
p-bar - the long-run percent defective.

21. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Can't tell without a Range chart.
95%
Variable.
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

22. Defect check sheets
Lean is waste reduction - Six Sigma is variation reduction.
Before production starts
Different types of defects are listed (used for Pareto chart)
Speed - courtesy - competence - and ease of repair.

23. FMEA
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 time series plot.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

24. Define perceived quality (Garvin's framework).
The secondary characteristics of a product; "bells and whistles."
Mistake-proofing.
Blame.
Brand image.

25. Define takt time.
The cycle time required to meet demand.
Large enough to find two of the attribute - on average.
Deming.
The Japanese national quality award.

26. Test for constant variance
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
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.
Rapid improvement process.

27. Histogram by Hand
Financial - customer - internal process - innovation and learning.
Define - measure - analyze - design - verify.
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
Prevention and appraisal costs are balanced against internal and external failure.

28. How are LQL and AQL determined in an acceptance sampling plan?
Through producer/consumer negotiation.
To do a capability study for a non-centered process.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
= yij - y(bar)i --> value minus sum of that treatment (of row)

29. What is the difference between Lean and Six Sigma?
Lean is waste reduction - Six Sigma is variation reduction.
Is the consequence of the failure.
Assigns scores to weighted criteria for each project under consideration.
Define - measure - analyze - design - verify.

30. What is DMADV?
Used to create frequency distribution tally sheets
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Define - measure - analyze - design - verify.
Assigns scores to weighted criteria for each project under consideration.

31. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
The number of standard deviations some value is from the mean.
5%
To do a capability study for a non-centered process.
Pleasing to the senses.

32. Define yield.
Define - measure - analyze - improve - control.
A time series plot.
The ratio of outputs to inputs; 1-scrap.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

33. A process is operating "in control." Does this mean the customer's requirements are met?
10 for Hazardous without warning 1 for none
The ability of a process to consistently meet customer specifications.
Define - measure - analyze - design - verify.
No -- only if the process is also capable.

34. Residual
Stratify a particular defect type according to logical criteria
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Fewer good units to sell - increased variable cost/unit.
Central Limit Theorem

35. Residual(eij)
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Fishbone - cause-and-effect diagram.
Someone who is consistently against virtually everything.
= yij - y(bar)i --> value minus sum of that treatment (of row)

36. What is an affinity diagram?
Central Limit Theorem
The gap between what management thinks customers want and what customers really want.
Consumer risk.
A brainstorming tool that shows the connections between ideas.

37. Failure Mode
Sort - Set in Order - Shine - Standardize - Sustain
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).
Is the way in which the failure is manifested.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

38. What are the four categories of costs in Juran's framework?
Shifts - Trends - Repeating patterns - Correlation with known events
Prevention - appraisal - internal failure - external failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
A random variable that summarizes the information from the sample(s).

39. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Brand image.
Fewer good units to sell - increased variable cost/unit.
Attribute
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

40. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Speed - courtesy - competence - and ease of repair.

41. 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?
Concluding there has not been an effect/change when there has.
Conformance to specifications.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
False - because each machine will have different natural tolerances.

42. Taguchi's experimental designs are of this type.
Fractional factorial designs (orthogonal arrays)
Stratify a particular defect type according to logical criteria
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
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

43. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Define - measure - analyze - improve - control.
No -- the variation also has to be random and "expected."
Lean (or JIT).
A time series plot.

44. Complete this quality phrase: 'Fix the process - not the _____.'
10 for Hazardous without warning 1 for none
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
The gap between specifications and how service is performed.
Blame.

45. Disadvantages of DOE

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46. DOE
A diagram that shows the relationships between activities in a project network.
No -- only if the process is also capable.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

47. In a Z table - what is Z?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A random variable that summarizes the information from the sample(s).
The number of standard deviations some value is from the mean.
The gap between what is promised and what is delivered.

48. If a three-stage process has 90% yields at each stage - what is the overall yield?
100%
Mean time to failure.
The manager in charge of a process being improved in a Six Sigma project.
0.9^3 or 72.9%

49. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
A time series plot.
They move closer to the center line.
Lower control limit.

50. What is Type 1 Error?
Concluding there has been an effect/change when there has not.
Outside.
Actual drawings - layouts - maps - etc which show where a defect occurs
50%