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

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2. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
95%
Critical to quality.
Controlling quality at the source.
= yij - y(bar)i --> value minus sum of that treatment (of row)

3. What is the difference between the way sampling is done for SPC and for acceptance sampling?
No -- the variation also has to be random and "expected."
Fewer good units to sell - increased variable cost/unit.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Sampling for SPC is done real time.

4. With Six Sigma capability - how many defects per million opportunities would you see?
68%
Technical quality is the "what" of the service; functional quality is the "how."
3.4 (assuming 1.5 sigma shift in the mean)
Studying firms with the best performance in a particular area.

5. Failure cause
Is what induces the failure
No -- if it is not the same - it can only be worse!
An assertion or conjecture concerning one or more populations
It's good -- but it's still out of control!

6. Who first studied randomness in industrial processes
Walter A. Shewhart
Pleasing to the senses.
To monitor a process when measurement by variables is used.
Studying firms with the best performance in a particular area.

7. What does the abbreviation LCL stand for?
Waste.
Lower control limit.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Represents the behavior of a process

8. When yields decrease - what are the two effects on contribution?
What the value of the dependent variable is when the independent variable is zero.
Observed variation in response is caused by the input
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.
Fewer good units to sell - increased variable cost/unit.

9. In the Service Quality Gap Model - what is Gap 2?
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:
Financial - customer - internal process - innovation and learning.
5%
The gap between what management thinks customers want and the process specifications.

10. Definition of Interaction
The House of Quality.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
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 tool that shows performance along key dimensions all at once.

11. FMEA
Used to create frequency distribution tally sheets
Not necessarily.
It looks to minimize the probability of a failure - or to minimize its effects
Fewer good units to sell - increased variable cost/unit.

12. Risk Priority Number RPN
They move closer to the center line.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
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
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

13. What is Jidoka?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Controlling quality at the source.
The US national quality award.

14. Presence of interaction effect
Hold all input variables constant except one. Observe the response as you vary the single input.
Initiated before or at design concept finalization
A time series plot.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

15. Detection Criteria Ranking
Technical quality is the "what" of the service; functional quality is the "how."
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
10 if Almost impossible to detect
Attribute.

16. What is the Deming Prize?
The Japanese national quality award.
Lean is waste reduction - Six Sigma is variation reduction.
To monitor a process when measurement by attribute is used.
The gap between what customers expect and the service they receive.

17. What are the three main categories of assignable cause?
Fractional factorial designs (orthogonal arrays)
Workers - machines - materials.
What the value of the dependent variable is when the independent variable is zero.
Before production starts

18. In a regression - what does the standard error of the estimate tell you?
Hold all input variables constant except one. Observe the response as you vary the single input.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Fishbone - cause-and-effect diagram.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

19. In the Service Quality Gap Model - what is Gap 4?
To mentor/coach (and sometimes train) black belts.
The gap between what management thinks customers want and what customers really want.
Stratify a particular defect type according to logical criteria
The gap between what is promised and what is delivered.

20. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
Observed variation in response is caused by the input
100%
The gap between what management thinks customers want and the process specifications.
Hold all input variables constant except one. Observe the response as you vary the single input.

21. Disadvantages of DOE

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22. Process occurance ranking
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Initiated before or at design concept finalization
Causes that lead to a particular effect.
Failure Modes and Effects Analysis

23. 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.
A random variable that summarizes the information from the sample(s).
To monitor a process when measurement by attribute is used.
A brainstorming tool that shows the connections between ideas.

24. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Outside.
Inventory = throughput x flow time.
Walter A. Shewhart
A diagram that shows the relationships between activities in a project network.

25. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
Supplier - input - process - output - customer.
Is what induces the failure
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

26. What is CTQ?
Mistake-proofing.
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).
Fishbone - cause-and-effect diagram.
Critical to quality.

27. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
99.73%
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
A tool that shows the physical flows through a space.
68%

28. Uses of regression
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Initiated before or at design concept finalization
Large enough to find two of the attribute - on average.
Someone who is consistently against virtually everything.

29. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
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).

30. PFMEA
Before production starts
No -- the variation also has to be random and "expected."
=sqrt((p*(1-p)/n)
Method developed by Ishikawa to graphically display the causes of any given problem

31. Residual
The gap between what management thinks customers want and the process specifications.
Initiated before or at design concept finalization
Observed variation in response is caused by the input
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

32. TWO-DIMENTIONAL SCATTER PLOT
An assertion or conjecture concerning one or more populations
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Scrap - rework - retest - downtime - yield losses - disposition costs.
Is the consequence of the failure.

33. Which type of SPC measurement is more precise - variable or attribute?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Stratify a particular defect type according to logical criteria
A brainstorming tool that shows the connections between ideas.
Variable.

34. What is Little's Law?
Kaoru Ishikawa.
A brainstorming tool that shows the connections between ideas.
Inventory = throughput x flow time.
50%

35. Process check sheets
Upper control limit.
Waste.
Used to create frequency distribution tally sheets
The number of standard deviations some value is from the mean.

36. Design of Experiments (DOE) approach
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Central Limit Theorem
50%
10 for Hazardous without warning 1 for none

37. F value
F_alpha - df(tr) - df (error)
QFD
Used to create frequency distribution tally sheets
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

38. What is the role of a black belt?
No -- only if the process is also capable.
To monitor a process when measurement by attribute is used.
To manage the Six Sigma project.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

39. Histogram by Hand
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.
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:
Fishbone - cause-and-effect diagram.

40. If you can only collect categorical data - what type of SPC charting can you do?
Prevention and appraisal costs are balanced against internal and external failure.
An assertion or conjecture concerning one or more populations
Attribute.
The number of standard deviations some value is from the mean.

41. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
= yij - y(bar)i --> value minus sum of that treatment (of row)
Linearity - normality - homoscedasticity - independence.
No -- the variation also has to be random and "expected."
Through producer/consumer negotiation.

42. What size should samples be for attribute SPC?
10 for Hazardous without warning 1 for none
Prevention and appraisal costs are balanced against internal and external failure.
No -- the variation also has to be random and "expected."
Large enough to find two of the attribute - on average.

43. List two components of external failure.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Look for the assignable cause of non-random variation.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

44. 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.
To monitor a process when measurement by attribute is used.
The cycle time required to meet demand.
Large enough to find two of the attribute - on average.

45. ANOVA

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46. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
Because the mean and standard deviation are independent of each other.
The gap between what management thinks customers want and the process specifications.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

47. Which quality guru developed the concept of loss to society?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Taguchi
Defects Per Million Opportunities
QFD

48. Residual(eij)
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
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.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
= yij - y(bar)i --> value minus sum of that treatment (of row)

49. Define takt time.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
The cycle time required to meet demand.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

50. FMEA
3.4 (assuming 1.5 sigma shift in the mean)
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 ability of a process to consistently meet customer specifications.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces