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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. Design of Experiments (DOE) approach
68%
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Concluding there has been an effect/change when there has not.
Mean time to replacement.

2. What is the role of a black belt?
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
Sort - Set in Order - Shine - Standardize - Sustain
To manage the Six Sigma project.
A descending order-sorted bar chart with a cumulative percentage line.

3. DFMEA
Central Limit Theorem
Large enough to find two of the attribute - on average.
The gap between what is promised and what is delivered.
Initiated before or at design concept finalization

4. What is FMEA?
Failure Modes and Effects Analysis
Actual drawings - layouts - maps - etc which show where a defect occurs
Variable.
Because the mean and standard deviation are independent of each other.

5. What are the three main categories of assignable cause?
The gap between what management thinks customers want and what customers really want.
To monitor a process when measurement by attribute is used.
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
Workers - machines - materials.

6. Manual Test for Nomality
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Consumer risk.
Is the way in which the failure is manifested.
Central Limit Theorem

7. What graphical tool is used to show the relationship between two numerical variables?
Supplier - input - process - output - customer.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Technical quality is the "what" of the service; functional quality is the "how."
A scatterplot.

8. What is the role of a master black belt?
Waste.
Consumer risk.
To mentor/coach (and sometimes train) black belts.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

9. 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?
Define - measure - analyze - design - verify.
False - because each machine will have different natural tolerances.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
A tool that shows performance along key dimensions all at once.

10. What does SIPOC stand for?
0.9^3 or 72.9%
Supplier - input - process - output - customer.
Causes that lead to a particular effect.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

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

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12. For what is a p-chart used?
An assertion or conjecture concerning one or more populations
The gap between what management thinks customers want and the process specifications.
To monitor a process when measurement by attribute is used.
A tool that shows the physical flows through a space.

13. When is Cpk used?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Organize ideas into meaningful categories by recognizing their underlying similarity
The gap between what customers expect and the service they receive.
To do a capability study for a non-centered process.

14. Test for Independence
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
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).
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
If the Response vs. Levels graph if the response lines are not parallel (crossing)

15. Simple Regression Analysis (one factor regression model)
= 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
Lower skill requirements - faster - less chance for error.
The gap between what management thinks customers want and the process specifications.
A scatterplot.

16. In the Service Quality Gap Model - what is Gap 4?
Large enough to find two of the attribute - on average.
Defects Per Million Opportunities
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 gap between what is promised and what is delivered.

17. In a regression - what does the standard error of the estimate tell you?
A tool that shows where there is waste in a process.
p-bar - the long-run percent defective.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Lower skill requirements - faster - less chance for error.

18. What is Jidoka?
Controlling quality at the source.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Pleasing to the senses.
= 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

19. What does DMAIC stand for?
Prevention - appraisal - internal failure - external failure.
To obtain a certain desirable outcome from the process
100%
Define - measure - analyze - improve - control.

20. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
Not necessarily.
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
100%
Inventory = throughput x flow time.

21. Does it ever make sense to accept a job when a process is incapable?
To be a member of a Six Sigma project team.
Shifts - Trends - Repeating patterns - Correlation with known events
5%
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

22. What is the Deming Prize?
The Japanese national quality award.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
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:
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

23. What does the abbreviation LCL stand for?
Lower control limit.
A descending order-sorted bar chart with a cumulative percentage line.
Actual drawings - layouts - maps - etc which show where a defect occurs
Can't tell without a Range chart.

24. Effect ranking (Severity of the Defect)
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Waste.
The gap between what is promised and what is delivered.
10 for Hazardous without warning 1 for none

25. TWO-DIMENTIONAL SCATTER PLOT
Kaoru Ishikawa.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Large enough to find two of the attribute - on average.

26. 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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27. Who developed the fishbone diagram?
Technical quality is the "what" of the service; functional quality is the "how."
Kaoru Ishikawa.
A descending order-sorted bar chart with a cumulative percentage line.
The Japanese national quality award.

28. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
Fishbone - cause-and-effect diagram.
Supplier - input - process - output - customer.
The House of Quality.

29. What is an affinity diagram?
Used to create frequency distribution tally sheets
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
A brainstorming tool that shows the connections between ideas.
The gap between specifications and how service is performed.

30. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Sort - Set in Order - Shine - Standardize - Sustain
Concluding there has not been an effect/change when there has.
Lean (or JIT).
An assertion or conjecture concerning one or more populations

31. Definition of Interaction
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
A tool that shows performance along key dimensions all at once.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
It's good -- but it's still out of control!

32. What is the center line of an X-bar chart?
X-bar-bar
Mean time to failure.
It's good -- but it's still out of control!
Variable.

33. What does a project prioritization matrix do?
The Japanese national quality award.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
A tool that shows where there is waste in a process.
Assigns scores to weighted criteria for each project under consideration.

34. In a Z table - what is Z?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
3.4 (assuming 1.5 sigma shift in the mean)
Is what induces the failure
The number of standard deviations some value is from the mean.

35. Failure effect
Is the consequence of the failure.
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).
The target number of standard deviations from the mean for specifications.
Fitness for use.

36. Residual(eij)
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
= yij - y(bar)i --> value minus sum of that treatment (of row)
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Fractional factorial designs (orthogonal arrays)

37. Detection Criteria Ranking
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
A tool that shows performance along key dimensions all at once.
They move closer to the center line.
10 if Almost impossible to detect

38. Affinity Diagrams
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Organize ideas into meaningful categories by recognizing their underlying similarity
No -- if it is not the same - it can only be worse!
False - because each machine will have different natural tolerances.

39. F value
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
To manage the Six Sigma project.
F_alpha - df(tr) - df (error)
100%

40. DOE
The primary operating characteristics of a product.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
To monitor a process when measurement by variables is used.

41. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
False - because each machine will have different natural tolerances.
A brainstorming tool that shows the connections between ideas.
Technical quality is the "what" of the service; functional quality is the "how."

42. PFMEA
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Mean time to replacement.
Before production starts
Concluding there has not been an effect/change when there has.

43. The Test Statistic (TS)
To manage the Six Sigma project.
A random variable that summarizes the information from the sample(s).
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
A brainstorming tool that shows the connections between ideas.

44. In the Service Quality Gap Model - what is Gap 3?
Variable.
The gap between specifications and how service is performed.
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
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

45. In a regression - what does R-square tell you?
5%
A diagram that shows the relationships between activities in a project network.
To do a capability study for a non-centered process.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

46. Process check sheets
Prevention - appraisal - internal failure - external failure.
The ratio of outputs to inputs; 1-scrap.
Used to create frequency distribution tally sheets
Lean (or JIT).

47. What is the center line of a p-chart?
Mean time to replacement.
Concluding there has been an effect/change when there has not.
p-bar - the long-run percent defective.
Is the consequence of the failure.

48. Define features.
The secondary characteristics of a product; "bells and whistles."
Actual drawings - layouts - maps - etc which show where a defect occurs
Fractional factorial designs (orthogonal arrays)
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

49. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Lean is waste reduction - Six Sigma is variation reduction.
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

50. What is a Pareto chart?
To manage the Six Sigma project.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
A descending order-sorted bar chart with a cumulative percentage line.
Before production starts