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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. Histogram by Hand
False - because each machine will have different natural tolerances.
Scrap - rework - retest - downtime - yield losses - disposition costs.
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's good -- but it's still out of control!

2. What does the abbreviation LCL stand for?
Fractional factorial designs (orthogonal arrays)
Used to create frequency distribution tally sheets
Lower control limit.
Pleasing to the senses.

3. What type of risk is associated with Type 1 Error?
Producer risk.
Fewer good units to sell - increased variable cost/unit.
To monitor a process when measurement by attribute is used.
Mean time to replacement.

4. What do you do when a process is out of control?
Because the mean and standard deviation are independent of each other.
Look for the assignable cause of non-random variation.
It's good -- but it's still out of control!
Taguchi

5. In the Service Quality Gap Model - what is Gap 4?
Upper control limit.
The gap between what is promised and what is delivered.
Variable.
Organize ideas into meaningful categories by recognizing their underlying similarity

6. List Garvin's eight dimensions of product quality.
Is what induces the failure
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.
False - because each machine will have different natural tolerances.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

7. Explain the difference between technical and functional service quality.
Technical quality is the "what" of the service; functional quality is the "how."
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
95%
Initiated before or at design concept finalization

8. What graphical tool is used to show the relationship between two numerical variables?
No -- if it is not the same - it can only be worse!
Speed - courtesy - competence - and ease of repair.
Stratify a particular defect type according to logical criteria
A scatterplot.

9. What is Jidoka?
Controlling quality at the source.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Observed variation in response is caused by the input
Waste.

10. What is the role of a green belt?
To be a member of a Six Sigma project team.
Concluding there has not been an effect/change when there has.
Lower control limit.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

11. What is a dashboard?
Define - measure - analyze - improve - control.
Studying firms with the best performance in a particular area.
A tool that shows performance along key dimensions all at once.
Lean is waste reduction - Six Sigma is variation reduction.

12. What quality guru emphasizes management as a system?
Deming.
The manager in charge of a process being improved in a Six Sigma project.
Someone who is consistently against virtually everything.
The gap between what management thinks customers want and the process specifications.

13. What quality tool formally incorporates the voice of the customer?
Pleasing to the senses.
QFD
Causes that lead to a particular effect.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

14. Define benchmarking.
The primary operating characteristics of a product.
Kaoru Ishikawa.
Studying firms with the best performance in a particular area.
= 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

15. What are the Five Dimensions of Service Quality?
Lower control limit.
To obtain a certain desirable outcome from the process
Reliability - Assurance - Responsiveness - Tangibles - Empathy
10 if Almost impossible to detect

16. Design of Experiments (DOE) approach
They move closer to the center line.
The primary operating characteristics of a product.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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

17. Define durability.
Pleasing to the senses.
Mean time to replacement.
Lower skill requirements - faster - less chance for error.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

18. Failure effect
Is the consequence of the failure.
A brainstorming tool that shows the connections between ideas.
Mean time to failure.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

19. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Waste.
Sampling for SPC is done real time.
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).
The gap between what customers expect and the service they receive.

20. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
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).
100%
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
A tool that shows performance along key dimensions all at once.

21. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
99.73%
Consumer risk.
Lower skill requirements - faster - less chance for error.
Through producer/consumer negotiation.

22. Define takt time.
The cycle time required to meet demand.
5%
Mistake-proofing.
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. Which type of SPC measurement is more precise - variable or attribute?
95%
F_alpha - df(tr) - df (error)
Organize ideas into meaningful categories by recognizing their underlying similarity
Variable.

24. Does it ever make sense to accept a job when a process is incapable?
p-bar - the long-run percent defective.
Lean (or JIT).
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Variable.

25. In the Service Quality Gap Model - what is Gap 3?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Stratify a particular defect type according to logical criteria
The gap between specifications and how service is performed.
Concluding there has been an effect/change when there has not.

26. Who developed the fishbone diagram?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
A tool that shows performance along key dimensions all at once.
Kaoru Ishikawa.
Upper control limit.

27. What does the abbreviation UCL stand for?
Fewer good units to sell - increased variable cost/unit.
Upper control limit.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

28. Complete this quality phrase: 'Fix the process - not the _____.'
To manage the Six Sigma project.
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
Blame.
Initiated before or at design concept finalization

29. What is the Baldrige Award?
The US national quality award.
50%
68%
A tool that shows performance along key dimensions all at once.

30. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
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:
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
A diagram that shows the relationships between activities in a project network.

31. List two components of prevention cost.
Studying firms with the best performance in a particular area.
Controlling quality at the source.
Lower skill requirements - faster - less chance for error.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

32. Define conformance quality.
Rapid improvement process.
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).
A diagram that shows the relationships between activities in a project network.
The degree to which a product meets pre-established standards.

33. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
A random variable that summarizes the information from the sample(s).
Waste.
No -- the variation also has to be random and "expected."
To monitor a process when measurement by attribute is used.

34. What does SIPOC stand for?
Lean (or JIT).
The Japanese national quality award.
To mentor/coach (and sometimes train) black belts.
Supplier - input - process - output - customer.

35. Test for constant variance
The manager in charge of a process being improved in a Six Sigma project.
A tool that shows the physical flows through a space.
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.
Defects Per Million Opportunities

36. For what is an x-bar chart used?
To monitor a process when measurement by variables is used.
An assertion or conjecture concerning one or more populations
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Upper control limit.

37. Risk Priority Number RPN
Mistake-proofing.
What the value of the dependent variable is when the independent variable is zero.
Upper control limit.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

38. Who is a process owner?
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 manager in charge of a process being improved in a Six Sigma project.
Studying firms with the best performance in a particular area.
Method developed by Ishikawa to graphically display the causes of any given problem

39. Uses of regression - Control
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Walter A. Shewhart
If the Response vs. Levels graph if the response lines are not parallel (crossing)
To obtain a certain desirable outcome from the process

40. What is Type II Error?
Concluding there has not been an effect/change when there has.
The gap between what is promised and what is delivered.
Initiated before or at design concept finalization
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

41. DFMEA
Not necessarily.
The number of standard deviations some value is from the mean.
Initiated before or at design concept finalization
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. What is FMEA?
Workers - machines - materials.
Variable.
= 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
Failure Modes and Effects Analysis

43. Simple Regression Analysis (one factor regression model)
Central Limit Theorem
No -- the variation also has to be random and "expected."
= 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
The gap between specifications and how service is performed.

44. Effect ranking (Severity of the Defect)
Walter A. Shewhart
The gap between what customers expect and the service they receive.
Critical to quality.
10 for Hazardous without warning 1 for none

45. In a regression - what does the standard error of the estimate tell you?
To manage the Six Sigma project.
The degree to which a product meets pre-established standards.
A scatterplot.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

46. What is the center line of a p-chart?
100%
p-bar - the long-run percent defective.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

47. When is Cpk used?
The gap between what customers expect and the service they receive.
To do a capability study for a non-centered process.
The primary operating characteristics of a product.
Inventory = throughput x flow time.

48. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
To monitor a process when measurement by attribute is used.
A diagram that shows the relationships between activities in a project network.
Observed variation in response is caused by the input

49. 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?
Large enough to find two of the attribute - on average.
False - because each machine will have different natural tolerances.
The secondary characteristics of a product; "bells and whistles."
95%

50. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Studying firms with the best performance in a particular area.
Attribute