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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. Failure Mode
Is the way in which the failure is manifested.
Method developed by Ishikawa to graphically display the causes of any given problem
Stratify a particular defect type according to logical criteria
The secondary characteristics of a product; "bells and whistles."

2. Simple Regression Analysis (one factor regression model)
Actual drawings - layouts - maps - etc which show where a defect occurs
The ratio of outputs to inputs; 1-scrap.
= 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
Not necessarily.

3. In the Service Quality Gap Model - what is Gap 3?
The gap between specifications and how service is performed.
The House of Quality.
Different types of defects are listed (used for Pareto chart)
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

4. FMEA
Lean is waste reduction - Six Sigma is variation reduction.
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
The gap between specifications and how service is performed.
A tool that shows performance along key dimensions all at once.

5. Based on what principal can we use the normal distribution assumptions for SPC?
The gap between specifications and how service is performed.
0.9^3 or 72.9%
No -- if it is not the same - it can only be worse!
Central Limit Theorem

6. What is DMADV?
Define - measure - analyze - design - verify.
Organize ideas into meaningful categories by recognizing their underlying similarity
Someone who is consistently against virtually everything.
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

7. What is the role of a black belt?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
To manage the Six Sigma project.
Workers - machines - materials.
Producer risk.

8. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Fewer good units to sell - increased variable cost/unit.
68%
To monitor a process when measurement by variables is used.
A descending order-sorted bar chart with a cumulative percentage line.

9. With Six Sigma capability - how many defects per million opportunities would you see?
= yij - y(bar)i --> value minus sum of that treatment (of row)
A tool that shows performance along key dimensions all at once.
3.4 (assuming 1.5 sigma shift in the mean)
A scatterplot.

10. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
To monitor a process when measurement by attribute is used.
50%
Mean time to failure.

11. Your production process meets customer specifications. Is your process in control?
The primary operating characteristics of a product.
Walter A. Shewhart
Not necessarily.
Workers - machines - materials.

12. FMEA
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
50%
It looks to minimize the probability of a failure - or to minimize its effects
Is the way in which the failure is manifested.

13. Pareto Analysis
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
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
To be a member of a Six Sigma project team.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

14. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
A diagram that shows the relationships between activities in a project network.
Conformance to specifications.
95%
What the value of the dependent variable is when the independent variable is zero.

15. Design of Experiments (DOE) approach
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Lower skill requirements - faster - less chance for error.
Blame.
= yij - y(bar)i --> value minus sum of that treatment (of row)

16. Define features.
10 if Almost impossible to detect
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
The House of Quality.
The secondary characteristics of a product; "bells and whistles."

17. Define conformance quality.
Hold all input variables constant except one. Observe the response as you vary the single input.
Initiated before or at design concept finalization
The degree to which a product meets pre-established standards.
Consumer risk.

18. In a Z table - what is Z?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The number of standard deviations some value is from the mean.
= 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
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

19. What does Crosby say about benchmarking?
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
Causes that lead to a particular effect.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

20. What is a run chart?
Sort - Set in Order - Shine - Standardize - Sustain
Attribute
A time series plot.
Consumer risk.

21. Does it ever make sense to accept a job when a process is incapable?
Define - measure - analyze - improve - control.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
The gap between specifications and how service is performed.
Initiated before or at design concept finalization

22. What is the difference between the way sampling is done for SPC and for acceptance sampling?
F_alpha - df(tr) - df (error)
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
It looks to minimize the probability of a failure - or to minimize its effects
Sampling for SPC is done real time.

23. What is CTQ?
The gap between what is promised and what is delivered.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Upper control limit.
Critical to quality.

24. What type of risk is associated with Type II Error?
Consumer risk.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Someone who is consistently against virtually everything.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

25. TWO-DIMENTIONAL SCATTER PLOT
Upper control limit.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
It's good -- but it's still out of control!
To manage the Six Sigma project.

26. What is the center line of a p-chart?
Taguchi
Causes that lead to a particular effect.
p-bar - the long-run percent defective.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

27. For what is an x-bar chart used?
The manager in charge of a process being improved in a Six Sigma project.
A descending order-sorted bar chart with a cumulative percentage line.
Before production starts
To monitor a process when measurement by variables is used.

28. PFMEA
Fishbone - cause-and-effect diagram.
No -- if it is not the same - it can only be worse!
Before production starts
Conformance to specifications.

29. Affinity Diagrams
To do a capability study for a non-centered process.
Organize ideas into meaningful categories by recognizing their underlying similarity
Method developed by Ishikawa to graphically display the causes of any given problem
To be a member of a Six Sigma project team.

30. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Causes that lead to a particular effect.
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).
Assigns scores to weighted criteria for each project under consideration.
Variable.

31. What is an affinity diagram?
Studying firms with the best performance in a particular area.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
A brainstorming tool that shows the connections between ideas.
To mentor/coach (and sometimes train) black belts.

32. Advantages of DOE
A diagram that shows the relationships between activities in a project network.
50%
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
Actual drawings - layouts - maps - etc which show where a defect occurs

33. Taguchi's experimental designs are of this type.
Fractional factorial designs (orthogonal arrays)
To monitor a process when measurement by attribute is used.
Represents the behavior of a process
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

34. How are LQL and AQL determined in an acceptance sampling plan?
Through producer/consumer negotiation.
Before production starts
Look for the assignable cause of non-random variation.
Is the consequence of the failure.

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

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36. What does the abbreviation LCL stand for?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The target number of standard deviations from the mean for specifications.
Lower control limit.

37. Define product reliability.
68%
95%
To be a member of a Six Sigma project team.
Mean time to failure.

38. If you have calculated a Cpk - should you also calculate a Cp?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Not necessarily.
To obtain a certain desirable outcome from the process
Waste.

39. Define serviceability.
Speed - courtesy - competence - and ease of repair.
To be a member of a Six Sigma project team.
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:
Kaoru Ishikawa.

40. What is the Baldrige Award?
To mentor/coach (and sometimes train) black belts.
95%
The US national quality award.
Lower skill requirements - faster - less chance for error.

41. What are the three main categories of assignable cause?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
To manage the Six Sigma project.
Workers - machines - materials.
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

42. When is Cpk used?
Organize ideas into meaningful categories by recognizing their underlying similarity
To do a capability study for a non-centered process.
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) Plot a Line chart of the data in time sequence 2) Draw a line at the median

43. What does DMAIC stand for?
Define - measure - analyze - improve - control.
Initiated before or at design concept finalization
5%
To obtain a certain desirable outcome from the process

44. Test for constant variance
Scrap - rework - retest - downtime - yield losses - disposition costs.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
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

45. Define yield.
10 if Almost impossible to detect
Studying firms with the best performance in a particular area.
The ratio of outputs to inputs; 1-scrap.
Attribute

46. What is Little's Law?
Inventory = throughput x flow time.
To obtain a certain desirable outcome from the process
The ability of a process to consistently meet customer specifications.
Method developed by Ishikawa to graphically display the causes of any given problem

47. In the Service Quality Gap Model - what is Gap 2?
Is what induces the failure
The gap between what management thinks customers want and what customers really want.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The gap between what management thinks customers want and the process specifications.

48. What are two other names for an Ishikawa diagram?
Fishbone - cause-and-effect diagram.
The ratio of outputs to inputs; 1-scrap.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Defects Per Million Opportunities

49. List Garvin's eight dimensions of product quality.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Method developed by Ishikawa to graphically display the causes of any given problem
A random variable that summarizes the information from the sample(s).
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

50. DFMEA
Consumer risk.
Initiated before or at design concept finalization
Controlling quality at the source.
If the Response vs. Levels graph if the response lines are not parallel (crossing)