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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?
To mentor/coach (and sometimes train) black belts.
Lean (or JIT).
An assertion or conjecture concerning one or more populations
To obtain a certain desirable outcome from the process

2. Which type of SPC measurement is more precise - variable or attribute?
50%
Variable.
Scrap - rework - retest - downtime - yield losses - disposition costs.
No -- only if the process is also capable.

3. What is Kaizen?
Sort - Set in Order - Shine - Standardize - Sustain
To manage the Six Sigma project.
It's good -- but it's still out of control!
Rapid improvement process.

4. Pareto Analysis
Define - measure - analyze - improve - control.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
X-bar-bar
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

5. What do you do when a process is out of control?
QFD
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Mean time to failure.
Look for the assignable cause of non-random variation.

6. Presence of interaction effect
If the Response vs. Levels graph if the response lines are not parallel (crossing)
68%
The secondary characteristics of a product; "bells and whistles."
Concluding there has not been an effect/change when there has.

7. What are two other names for an Ishikawa diagram?
50%
The secondary characteristics of a product; "bells and whistles."
The ability of a process to consistently meet customer specifications.
Fishbone - cause-and-effect diagram.

8. What is an affinity diagram?
A brainstorming tool that shows the connections between ideas.
The degree to which a product meets pre-established standards.
Initiated before or at design concept finalization
A random variable that summarizes the information from the sample(s).

9. If a three-stage process has 90% yields at each stage - what is the overall yield?
Mistake-proofing.
The Japanese national quality award.
0.9^3 or 72.9%
Technical quality is the "what" of the service; functional quality is the "how."

10. When is Cpk used?
To do a capability study for a non-centered process.
68%
Blame.
Fitness for use.

11. Who first studied randomness in industrial processes
The cycle time required to meet demand.
Walter A. Shewhart
Waste.
The gap between what management thinks customers want and the process specifications.

12. What is Jidoka?
Controlling quality at the source.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
68%
Actual drawings - layouts - maps - etc which show where a defect occurs

13. What is a run chart?
A time series plot.
3.4 (assuming 1.5 sigma shift in the mean)
An assertion or conjecture concerning one or more populations
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

14. What is poka yoke?
Mistake-proofing.
Lean is waste reduction - Six Sigma is variation reduction.
= 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
Workers - machines - materials.

15. What graphical tool is used to show the relationship between two numerical variables?
Hold all input variables constant except one. Observe the response as you vary the single input.
A scatterplot.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Blame.

16. 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
A diagram that shows the relationships between activities in a project network.
What the value of the dependent variable is when the independent variable is zero.
Large enough to find two of the attribute - on average.

17. What is DPMO?
Defects Per Million Opportunities
p-bar - the long-run percent defective.
10 for Hazardous without warning 1 for none
The gap between what is promised and what is delivered.

18. What is a spaghetti diagram?
The gap between what management thinks customers want and what customers really want.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
A tool that shows the physical flows through a space.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

19. Define takt time.
The cycle time required to meet demand.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
The gap between what is promised and what is delivered.
The gap between what management thinks customers want and what customers really want.

20. What is process capability?
Fractional factorial designs (orthogonal arrays)
Because the mean and standard deviation are independent of each other.
=sqrt((p*(1-p)/n)
The ability of a process to consistently meet customer specifications.

21. What are the Five Dimensions of Service Quality?
To monitor a process when measurement by attribute is used.
Inventory = throughput x flow time.
To obtain a certain desirable outcome from the process
Reliability - Assurance - Responsiveness - Tangibles - Empathy

22. One factor at a time (OFAT)
3.4 (assuming 1.5 sigma shift in the mean)
A tool that shows the physical flows through a space.
Supplier - input - process - output - customer.
Hold all input variables constant except one. Observe the response as you vary the single input.

23. What is a CAVE man?
Someone who is consistently against virtually everything.
p-bar - the long-run percent defective.
Concluding there has not been an effect/change when there has.
A scatterplot.

24. Test for constant variance
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.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Sampling for SPC is done real time.
Waste.

25. Taguchi's experimental designs are of this type.
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).
Blame.
Fractional factorial designs (orthogonal arrays)
Define - measure - analyze - design - verify.

26. What does DMAIC stand for?
The manager in charge of a process being improved in a Six Sigma project.
To be a member of a Six Sigma project team.
Pleasing to the senses.
Define - measure - analyze - improve - control.

27. List two components of internal failure.
Organize ideas into meaningful categories by recognizing their underlying similarity
Scrap - rework - retest - downtime - yield losses - disposition costs.
Mistake-proofing.
Concluding there has been an effect/change when there has not.

28. How does Juran define quality?
The gap between specifications and how service is performed.
Fitness for use.
The amount of variation in the dependent variable that is explained by the variation in 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

29. List two components of external failure.
Controlling quality at the source.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Initiated before or at design concept finalization

30. What is the Baldrige Award?
Walter A. Shewhart
Deming.
The US national quality award.
5%

31. 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.
A diagram that shows the relationships between activities in a project network.
The manager in charge of a process being improved in a Six Sigma project.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

32. DOE
The number of standard deviations some value is from the mean.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Concluding there has not been an effect/change when there has.
Lower skill requirements - faster - less chance for error.

33. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
68%
A tool that shows the physical flows through a space.
Concluding there has been an effect/change when there has not.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

34. Statistical Hypothesis
A brainstorming tool that shows the connections between ideas.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Lean (or JIT).
An assertion or conjecture concerning one or more populations

35. Affinity Diagrams
Studying firms with the best performance in a particular area.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Organize ideas into meaningful categories by recognizing their underlying similarity
No -- only if the process is also capable.

36. Regression
Represents the behavior of a process
The US national quality award.
Fishbone - cause-and-effect diagram.
False - because each machine will have different natural tolerances.

37. 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?
False - because each machine will have different natural tolerances.
Studying firms with the best performance in a particular area.
A random variable that summarizes the information from the sample(s).
To do a capability study for a non-centered process.

38. Stratified defect check sheets
Failure Modes and Effects Analysis
Stratify a particular defect type according to logical criteria
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The Japanese national quality award.

39. What is a histogram?
68%
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
A tool that shows the physical flows through a space.
Fitness for use.

40. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
No -- only if the process is also capable.
Fitness for use.
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).
Outside.

41. What is muda
= yij - y(bar)i --> value minus sum of that treatment (of row)
Waste.
The degree to which a product meets pre-established standards.
0.9^3 or 72.9%

42. For what is an x-bar chart used?
Shows the temporal flow of activities in a project network.
To monitor a process when measurement by variables is used.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
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. Complete this quality phrase: 'Fix the process - not the _____.'
Initiated before or at design concept finalization
Causes that lead to a particular effect.
Technical quality is the "what" of the service; functional quality is the "how."
Blame.

44. Non-random patterns (Run Charts)
Shifts - Trends - Repeating patterns - Correlation with known events
= yij - y(bar)i --> value minus sum of that treatment (of row)
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Can't tell without a Range chart.

45. What is the role of a green belt?
Upper control limit.
Mistake-proofing.
Look for the assignable cause of non-random variation.
To be a member of a Six Sigma project team.

46. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Controlling quality at the source.
No -- the variation also has to be random and "expected."
The gap between what customers expect and the service they receive.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

47. Effect ranking (Severity of the Defect)
A random variable that summarizes the information from the sample(s).
Prevention and appraisal costs are balanced against internal and external failure.
Central Limit Theorem
10 for Hazardous without warning 1 for none

48. The Test Statistic (TS)
A random variable that summarizes the information from the sample(s).
To monitor a process when measurement by attribute is used.
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
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

49. What size should samples be for attribute SPC?
Taguchi
Large enough to find two of the attribute - on average.
Linearity - normality - homoscedasticity - independence.
Controlling quality at the source.

50. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
Hold all input variables constant except one. Observe the response as you vary the single input.
Large enough to find two of the attribute - on average.
A descending order-sorted bar chart with a cumulative percentage line.