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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. DFMEA
Consumer risk.
The ability of a process to consistently meet customer specifications.
Initiated before or at design concept finalization
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

2. What is the formula for standard deviation?
10 if Almost impossible to detect
=sqrt(Σ(x-x-bar)^2)/(n-1))
99.73%
F_alpha - df(tr) - df (error)

3. What is DPMO?
Defects Per Million Opportunities
=sqrt(Σ(x-x-bar)^2)/(n-1))
Sort - Set in Order - Shine - Standardize - Sustain
Method developed by Ishikawa to graphically display the causes of any given problem

4. Defect check sheets
Causes that lead to a particular effect.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Different types of defects are listed (used for Pareto chart)
X-bar-bar

5. Failure cause
Is what induces the failure
Is the way in which the failure is manifested.
No -- only if the process is also capable.
The ability of a process to consistently meet customer specifications.

6. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Controlling quality at the source.
What the value of the dependent variable is when the independent variable is zero.
Outside.
Stratify a particular defect type according to logical criteria

7. DOE
What the value of the dependent variable is when the independent variable is zero.
The Japanese national quality award.
Variable.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

8. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Variable.
To monitor a process when measurement by attribute is used.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Outside.

9. Failure Mode
Reliability - Assurance - Responsiveness - Tangibles - Empathy
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
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
Is the way in which the failure is manifested.

10. What is a CAVE man?
The House of Quality.
The ratio of outputs to inputs; 1-scrap.
Someone who is consistently against virtually everything.
The target number of standard deviations from the mean for specifications.

11. What is the role of a master black belt?
No -- only if the process is also capable.
It looks to minimize the probability of a failure - or to minimize its effects
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
To mentor/coach (and sometimes train) black belts.

12. In the Service Quality Gap Model - what is Gap 2?
Mistake-proofing.
The gap between what management thinks customers want and the process specifications.
QFD
Lower skill requirements - faster - less chance for error.

13. If a three-stage process has 90% yields at each stage - what is the overall yield?
68%
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
0.9^3 or 72.9%
99.73%

14. 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
Lower control limit.
The ability of a process to consistently meet customer specifications.
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

15. What does a project prioritization matrix do?
To obtain a certain desirable outcome from the process
The gap between specifications and how service is performed.
Sampling for SPC is done real time.
Assigns scores to weighted criteria for each project under consideration.

16. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The gap between what management thinks customers want and what customers really want.
Lean (or JIT).
=sqrt((p*(1-p)/n)

17. What do you do when a process is out of control?
Is the way in which the failure is manifested.
Stratify a particular defect type according to logical criteria
Shifts - Trends - Repeating patterns - Correlation with known events
Look for the assignable cause of non-random variation.

18. One factor at a time (OFAT)
Failure Modes and Effects Analysis
Blame.
Hold all input variables constant except one. Observe the response as you vary the single input.
Is the consequence of the failure.

19. Uses of regression - Control
To obtain a certain desirable outcome from the process
Method developed by Ishikawa to graphically display the causes of any given problem
Central Limit Theorem
Reliability - Assurance - Responsiveness - Tangibles - Empathy

20. Creating a Run Chart
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Brand image.
Attribute
Technical quality is the "what" of the service; functional quality is the "how."

21. Based on what principal can we use the normal distribution assumptions for SPC?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Central Limit Theorem
A scatterplot.
A brainstorming tool that shows the connections between ideas.

22. What is a spaghetti diagram?
The ratio of outputs to inputs; 1-scrap.
A tool that shows the physical flows through a space.
Define - measure - analyze - improve - control.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

23. Risk Priority Number RPN
Walter A. Shewhart
Inventory = throughput x flow time.
Scrap - rework - retest - downtime - yield losses - disposition costs.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

24. Your production process meets customer specifications. Is your process in control?
Not necessarily.
The cycle time required to meet demand.
Assigns scores to weighted criteria for each project under consideration.
Causes that lead to a particular effect.

25. What is the center line of a p-chart?
Actual drawings - layouts - maps - etc which show where a defect occurs
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
Sampling for SPC is done real time.
p-bar - the long-run percent defective.

26. What is the formula for the standard deviation of a proportion?
99.73%
The Japanese national quality award.
=sqrt((p*(1-p)/n)
QFD

27. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
No -- the variation also has to be random and "expected."
Lower control limit.
Observed variation in response is caused by the input
QFD

28. Process check sheets
Used to create frequency distribution tally sheets
Blame.
p-bar - the long-run percent defective.
The primary operating characteristics of a product.

29. Why do you need two control charts for variables SPC?
Waste.
Defects Per Million Opportunities
Because the mean and standard deviation are independent of each other.
To monitor a process when measurement by attribute is used.

30. TWO-DIMENTIONAL SCATTER PLOT
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
It looks to minimize the probability of a failure - or to minimize its effects
The degree to which a product meets pre-established standards.
To monitor a process when measurement by attribute is used.

31. ANOVA

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32. Test for Independence
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
The gap between what management thinks customers want and what customers really want.
Upper control limit.
Because the mean and standard deviation are independent of each other.

33. What does the abbreviation UCL stand for?
Initiated before or at design concept finalization
Someone who is consistently against virtually everything.
Financial - customer - internal process - innovation and learning.
Upper control limit.

34. Defect location check sheets
Initiated before or at design concept finalization
Actual drawings - layouts - maps - etc which show where a defect occurs
Mean time to replacement.
To monitor a process when measurement by attribute is used.

35. Regression
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Represents the behavior of a process
Large enough to find two of the attribute - on average.
10 for Hazardous without warning 1 for none

36. What size should samples be for attribute SPC?
Large enough to find two of the attribute - on average.
Mistake-proofing.
The gap between what management thinks customers want and the process specifications.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

37. Which quality guru developed the concept of loss to society?
Taguchi
The manager in charge of a process being improved in a Six Sigma project.
Used to create frequency distribution tally sheets
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

38. List two components of external failure.
Deming.
Not necessarily.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Causes that lead to a particular effect.

39. You have been plotting sample means on an x-bar chart and all points indicate normal - expected variation. Is the process in control?

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40. Does it ever make sense to accept a job when a process is incapable?
Is the consequence of the failure.
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.
Producer risk.

41. What is FMEA?
Failure Modes and Effects Analysis
Lean is waste reduction - Six Sigma is variation reduction.
Through producer/consumer negotiation.
The number of standard deviations some value is from the mean.

42. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
Different types of defects are listed (used for Pareto chart)
Variable.
A tool that shows performance along key dimensions all at once.

43. List two appraisal costs.
68%
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:
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Studying firms with the best performance in a particular area.

44. What is a network diagram?
A diagram that shows the relationships between activities in a project network.
Brand image.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Consumer risk.

45. One factor at a time (OFAT)
Assigns scores to weighted criteria for each project under consideration.
Observed variation in response is caused by the input
Upper control limit.
Studying firms with the best performance in a particular area.

46. Which type of SPC measurement is more precise - variable or attribute?
Workers - machines - materials.
The gap between what customers expect and the service they receive.
The US national quality award.
Variable.

47. What are the four perspectives of the Balanced Scorecard?
To do a capability study for a non-centered process.
Financial - customer - internal process - innovation and learning.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

48. Process occurance ranking
The degree to which a product meets pre-established standards.
Mean time to failure.
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
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

49. Cause and Effect Diagrams
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Sort - Set in Order - Shine - Standardize - Sustain
Method developed by Ishikawa to graphically display the causes of any given problem
Define - measure - analyze - design - verify.

50. Define performance quality.
Actual drawings - layouts - maps - etc which show where a defect occurs
They move closer to the center line.
The primary operating characteristics of a product.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median