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

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2. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
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
They move closer to the center line.
Sampling for SPC is done real time.

3. What does Crosby say about benchmarking?
Observed variation in response is caused by the input
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
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

4. What percentage of a normal distribution lies above the mean?
50%
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Prevention and appraisal costs are balanced against internal and external failure.
A tool that shows the physical flows through a space.

5. What is the formula for standard deviation?
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:
Rapid improvement process.
=sqrt(Σ(x-x-bar)^2)/(n-1))
No -- only if the process is also capable.

6. Defect check sheets
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
10 if Almost impossible to detect
Different types of defects are listed (used for Pareto chart)
Kaoru Ishikawa.

7. Histogram by Hand
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
Financial - customer - internal process - innovation and learning.
Before production starts
Variable.

8. Failure effect
=sqrt(Σ(x-x-bar)^2)/(n-1))
The ratio of outputs to inputs; 1-scrap.
Is the consequence of the failure.
They move closer to the center line.

9. Which quality guru developed the concept of loss to society?
Taguchi
Stratify a particular defect type according to logical criteria
The number of standard deviations some value is from the mean.
The gap between what management thinks customers want and the process specifications.

10. What is a Gantt chart?
A tool that shows performance along key dimensions all at once.
To do a capability study for a non-centered process.
100%
Shows the temporal flow of activities in a project network.

11. One factor at a time (OFAT)
A scatterplot.
Central Limit Theorem
To monitor a process when measurement by variables is used.
Observed variation in response is caused by the input

12. ANOVA

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13. What do you do when a process is out of control?
Method developed by Ishikawa to graphically display the causes of any given problem
=sqrt((p*(1-p)/n)
A tool that shows the physical flows through a space.
Look for the assignable cause of non-random variation.

14. Residual(eij)
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Organize ideas into meaningful categories by recognizing their underlying similarity
= yij - y(bar)i --> value minus sum of that treatment (of row)
The secondary characteristics of a product; "bells and whistles."

15. Regression
Represents the behavior of a process
Central Limit Theorem
To manage the Six Sigma project.
The primary operating characteristics of a product.

16. When yields decrease - what are the two effects on contribution?
Fewer good units to sell - increased variable cost/unit.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Deming.

17. Which type of SPC measurement is more precise - variable or attribute?
Attribute
Defects Per Million Opportunities
Variable.
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

18. Residual
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)
Rapid improvement process.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

19. Manual Test for Nomality
Mean time to replacement.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
False - because each machine will have different natural tolerances.
Represents the behavior of a process

20. What is Little's Law?
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
Inventory = throughput x flow time.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Prevention - appraisal - internal failure - external failure.

21. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Sort - Set in Order - Shine - Standardize - Sustain
Concluding there has not been an effect/change when there has.

22. What is DPMO?
50%
Define - measure - analyze - improve - control.
Fewer good units to sell - increased variable cost/unit.
Defects Per Million Opportunities

23. Explain the difference between technical and functional service quality.
p-bar - the long-run percent defective.
Blame.
The number of standard deviations some value is from the mean.
Technical quality is the "what" of the service; functional quality is the "how."

24. What is a histogram?
They move closer to the center line.
Speed - courtesy - competence - and ease of repair.
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).
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

25. DOE
Prevention - appraisal - internal failure - external failure.
Shifts - Trends - Repeating patterns - Correlation with known events
An assertion or conjecture concerning one or more populations
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

26. Affinity Diagrams
A diagram that shows the relationships between activities in a project network.
Different types of defects are listed (used for Pareto chart)
The gap between what is promised and what is delivered.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

27. What quality tool formally incorporates the voice of the customer?
It looks to minimize the probability of a failure - or to minimize its effects
QFD
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

28. What type of risk is associated with Type 1 Error?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Producer risk.
Studying firms with the best performance in a particular area.
Lean (or JIT).

29. Does it ever make sense to accept a job when a process is incapable?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
A tool that shows the physical flows through a space.
Mean time to replacement.

30. What is a run chart?
Brand image.
A time series plot.
p-bar - the long-run percent defective.
Consumer risk.

31. Regression Analysis
Lower skill requirements - faster - less chance for error.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Through producer/consumer negotiation.

32. In a regression - what does the p value of F tell you?
To monitor a process when measurement by variables is used.
A scatterplot.
Walter A. Shewhart
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).

33. Daniel Test
Observed variation in response is caused by the input
50%
Prevention - appraisal - internal failure - 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:

34. List two components of prevention cost.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
A tool that shows where there is waste in a process.
Scrap - rework - retest - downtime - yield losses - disposition costs.

35. Define aesthetic quality.
It's good -- but it's still out of control!
Is what induces the failure
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Pleasing to the senses.

36. What is the center line of an X-bar chart?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
X-bar-bar
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

37. What is process capability?
The House of Quality.
Workers - machines - materials.
The ability of a process to consistently meet customer specifications.
Variable.

38. In the Service Quality Gap Model - what is Gap 3?
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.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The gap between specifications and how service is performed.
Concluding there has not been an effect/change when there has.

39. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Not necessarily.
Prevention and appraisal costs are balanced against internal and external failure.
An assertion or conjecture concerning one or more populations
5%

40. Definition of Interaction
Fewer good units to sell - increased variable cost/unit.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Method developed by Ishikawa to graphically display the causes of any given problem

41. What is the Baldrige Award?
To be a member of a Six Sigma project team.
The gap between what is promised and what is delivered.
Controlling quality at the source.
The US national quality award.

42. What is DMADV?
Define - measure - analyze - design - verify.
Fitness for use.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

43. TWO-DIMENTIONAL SCATTER PLOT
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
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.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Fishbone - cause-and-effect diagram.

44. Taguchi's experimental designs are of this type.
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
Fractional factorial designs (orthogonal arrays)
A tool that shows performance along key dimensions all at once.
The secondary characteristics of a product; "bells and whistles."

45. What is Jidoka?
Define - measure - analyze - improve - control.
Hold all input variables constant except one. Observe the response as you vary the single input.
Controlling quality at the source.
Financial - customer - internal process - innovation and learning.

46. What is Value Stream Mapping?
Speed - courtesy - competence - and ease of repair.
Concluding there has not been an effect/change when there has.
A tool that shows where there is waste in a process.
An assertion or conjecture concerning one or more populations

47. What is the Deming Prize?
The US national quality award.
The Japanese national quality award.
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
Stratify a particular defect type according to logical criteria

48. What does the abbreviation UCL stand for?
5%
Pleasing to the senses.
Upper control limit.
= yij - y(bar)i --> value minus sum of that treatment (of row)

49. Test for constant variance
Taguchi
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
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.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

50. What is a Gage R&R?
Concluding there has not been an effect/change when there has.
The gap between what management thinks customers want and what customers really want.
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).
Pleasing to the senses.