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Six Sigma

Subjects : certifications, six-sigma, business-skills

Instructions:

Answer 50 questions in 15 minutes.
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Match each statement with the correct term.
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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 a Gantt chart?
The secondary characteristics of a product; "bells and whistles."
Shows the temporal flow of activities in a project network.
The manager in charge of a process being improved in a Six Sigma project.
Studying firms with the best performance in a particular area.

2. What is the role of a master black belt?
Walter A. Shewhart
Different types of defects are listed (used for Pareto chart)
The gap between specifications and how service is performed.
To mentor/coach (and sometimes train) black belts.

3. Why do you need two control charts for variables SPC?
To monitor a process when measurement by variables is used.
A tool that shows performance along key dimensions all at once.
Because the mean and standard deviation are independent of each other.
Consumer risk.

4. What is Value Stream Mapping?
To do a capability study for a non-centered process.
A tool that shows where there is waste in a process.
Lower control limit.
Different types of defects are listed (used for Pareto chart)

5. In a Z table - what is Z?
Fewer good units to sell - increased variable cost/unit.
99.73%
The number of standard deviations some value is from the mean.
Mean time to replacement.

6. Affinity Diagrams
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The gap between what management thinks customers want and what customers really want.
The gap between specifications and how service is performed.
Organize ideas into meaningful categories by recognizing their underlying similarity

7. In the Service Quality Gap Model - what is Gap 2?
The gap between what management thinks customers want and the process specifications.
The gap between what management thinks customers want and what customers really want.
Deming.
The number of standard deviations some value is from the mean.

8. What are the three main categories of assignable cause?
Large enough to find two of the attribute - on average.
The House of Quality.
Workers - machines - materials.
=sqrt((p*(1-p)/n)

9. DFMEA
Initiated before or at design concept finalization
Reliability - Assurance - Responsiveness - Tangibles - Empathy
3.4 (assuming 1.5 sigma shift in the mean)
Variable.

10. What is poka yoke?
Mistake-proofing.
The degree to which a product meets pre-established standards.
Stratify a particular defect type according to logical criteria
Large enough to find two of the attribute - on average.

11. What is a histogram?
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.
A time series plot.
Brand image.

12. In the Service Quality Gap Model - what is Gap 5?
The gap between what customers expect and the service they receive.
The gap between specifications and how service is performed.
Financial - customer - internal process - innovation and learning.
Scrap - rework - retest - downtime - yield losses - disposition costs.

13. What type of risk is associated with Type II Error?
Consumer risk.
It's good -- but it's still out of control!
Look for the assignable cause of non-random variation.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

14. Who is a process owner?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
=sqrt((p*(1-p)/n)
The manager in charge of a process being improved in a Six Sigma project.
Financial - customer - internal process - innovation and learning.

15. FMEA
A descending order-sorted bar chart with a cumulative percentage line.
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
Kaoru Ishikawa.
Used to create frequency distribution tally sheets

16. Explain the difference between technical and functional service quality.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
It looks to minimize the probability of a failure - or to minimize its effects
The Japanese national quality award.
Technical quality is the "what" of the service; functional quality is the "how."

17. F value
F_alpha - df(tr) - df (error)
Assigns scores to weighted criteria for each project under consideration.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
A tool that shows the physical flows through a space.

18. Defect check sheets
The secondary characteristics of a product; "bells and whistles."
Mean time to replacement.
It looks to minimize the probability of a failure - or to minimize its effects
Different types of defects are listed (used for Pareto chart)

19. What is Type 1 Error?
Taguchi
Concluding there has been an effect/change when there has not.
Supplier - input - process - output - customer.
Consumer risk.

20. What is a network diagram?
The manager in charge of a process being improved in a Six Sigma project.
A diagram that shows the relationships between activities in a project network.
Because the mean and standard deviation are independent of each other.
A tool that shows the physical flows through a space.

21. What is a run chart?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
The degree to which a product meets pre-established standards.
Variable.
A time series plot.

22. Define serviceability.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Speed - courtesy - competence - and ease of repair.
Fishbone - cause-and-effect diagram.
The target number of standard deviations from the mean for specifications.

23. What is the difference between Lean and Six Sigma?
Organize ideas into meaningful categories by recognizing their underlying similarity
10 if Almost impossible to detect
Linearity - normality - homoscedasticity - independence.
Lean is waste reduction - Six Sigma is variation reduction.

24. List Garvin's eight dimensions of product quality.
Sampling for SPC is done real time.
No -- if it is not the same - it can only be worse!
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

25. What is the role of a black belt?
Represents the behavior of a process
100%
Shifts - Trends - Repeating patterns - Correlation with known events
To manage the Six Sigma project.

26. When yields decrease - what are the two effects on contribution?
A descending order-sorted bar chart with a cumulative percentage line.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Fewer good units to sell - increased variable cost/unit.
Stratify a particular defect type according to logical criteria

27. Your production process meets customer specifications. Is your process in control?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Concluding there has been an effect/change when there has not.
Not necessarily.
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

28. 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
Sampling for SPC is done real time.
100%
A time series plot.

29. Define aesthetic quality.
Pleasing to the senses.
The secondary characteristics of a product; "bells and whistles."
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
10 for Hazardous without warning 1 for none

30. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
Lower control limit.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Look for the assignable cause of non-random variation.

31. Non-random patterns (Run Charts)
Rapid improvement process.
The primary operating characteristics of a product.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Shifts - Trends - Repeating patterns - Correlation with known events

32. Failure Mode
Can't tell without a Range chart.
Is the way in which the failure is manifested.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Shows the temporal flow of activities in a project network.

33. What does Crosby say about benchmarking?
Attribute.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Lower skill requirements - faster - less chance for error.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

34. For what is an x-bar chart used?
To monitor a process when measurement by variables is used.
=sqrt(Σ(x-x-bar)^2)/(n-1))
A time series plot.
Mistake-proofing.

35. Name the structure associated with Quality Function Deployment.
Outside.
Stratify a particular defect type according to logical criteria
Mistake-proofing.
The House of Quality.

36. If you can only collect categorical data - what type of SPC charting can you do?
Attribute.
It looks to minimize the probability of a failure - or to minimize its effects
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Brand image.

37. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
Fishbone - cause-and-effect diagram.
100%
It's good -- but it's still out of control!

38. Define benchmarking.
Causes that lead to a particular effect.
Represents the behavior of a process
Lean is waste reduction - Six Sigma is variation reduction.
Studying firms with the best performance in a particular area.

39. What is Type II Error?
5%
Concluding there has not been an effect/change when there has.
0.9^3 or 72.9%
A brainstorming tool that shows the connections between ideas.

40. With Six Sigma capability - how many defects per million opportunities would you see?
Assigns scores to weighted criteria for each project under consideration.
Is the way in which the failure is manifested.
A diagram that shows the relationships between activities in a project network.
3.4 (assuming 1.5 sigma shift in the mean)

41. What is the formula for the standard deviation of a proportion?
The gap between what management thinks customers want and what customers really want.
Initiated before or at design concept finalization
=sqrt((p*(1-p)/n)
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

42. Process check sheets
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Lean (or JIT).
The gap between what management thinks customers want and the process specifications.
Used to create frequency distribution tally sheets

43. What is the Baldrige Award?
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 degree to which a product meets pre-established standards.
The US national quality award.
What the value of the dependent variable is when the independent variable is zero.

44. What is DMADV?
It looks to minimize the probability of a failure - or to minimize its effects
The gap between what management thinks customers want and what customers really want.
=sqrt((p*(1-p)/n)
Define - measure - analyze - design - verify.

45. Creating a Run Chart
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The secondary characteristics of a product; "bells and whistles."
Define - measure - analyze - design - verify.

46. What quality guru emphasizes management as a system?
To mentor/coach (and sometimes train) black belts.
Taguchi
A tool that shows performance along key dimensions all at once.
Deming.

47. Who developed the fishbone diagram?
10 for Hazardous without warning 1 for none
Speed - courtesy - competence - and ease of repair.
What the value of the dependent variable is when the independent variable is zero.
Kaoru Ishikawa.

48. Advantages of DOE
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
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Different types of defects are listed (used for Pareto chart)

49. List two appraisal costs.
The cycle time required to meet demand.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
50%
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

50. What does a project prioritization matrix do?
Observed variation in response is caused by the input
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:
100%
Assigns scores to weighted criteria for each project under consideration.

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Six Sigma

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