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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. What is an affinity diagram?
A brainstorming tool that shows the connections between ideas.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Fitness for use.
The secondary characteristics of a product; "bells and whistles."

2. What is poka yoke?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Mistake-proofing.
Look for the assignable cause of non-random variation.
A scatterplot.

3. What quality tool formally incorporates the voice of the customer?
QFD
To monitor a process when measurement by variables is used.
Financial - customer - internal process - innovation and learning.
Attribute.

4. List Garvin's eight dimensions of product quality.
A time series plot.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
To manage the Six Sigma project.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

5. Who first studied randomness in industrial processes
Walter A. Shewhart
10 if Almost impossible to detect
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

6. What are the three main categories of assignable cause?
10 if Almost impossible to detect
Workers - machines - materials.
A random variable that summarizes the information from the sample(s).
A descending order-sorted bar chart with a cumulative percentage line.

7. What graphical tool is used to show the relationship between two numerical variables?
They move closer to the center line.
A scatterplot.
Lower skill requirements - faster - less chance for error.
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

8. Residual(eij)
= yij - y(bar)i --> value minus sum of that treatment (of row)
Concluding there has been an effect/change when there has not.
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 target number of standard deviations from the mean for specifications.

9. List two appraisal costs.
Because the mean and standard deviation are independent of each other.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Lower skill requirements - faster - less chance for error.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

10. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Prevention and appraisal costs are balanced against internal and external failure.
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).
0.9^3 or 72.9%
Initiated before or at design concept finalization

11. Disadvantages of DOE

12. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
To monitor a process when measurement by attribute is used.
To mentor/coach (and sometimes train) black belts.
A descending order-sorted bar chart with a cumulative percentage line.

13. In the Service Quality Gap Model - what is Gap 1?
Define - measure - analyze - design - verify.
The degree to which a product meets pre-established standards.
The gap between what management thinks customers want and what customers really want.
No -- the variation also has to be random and "expected."

14. Which quality guru developed the concept of loss to society?
The gap between specifications and how service is performed.
Taguchi
Scrap - rework - retest - downtime - yield losses - disposition costs.
50%

15. What type of risk is associated with Type II Error?
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
3.4 (assuming 1.5 sigma shift in the mean)
Consumer risk.

16. Test for constant variance
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:
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.
No -- if it is not the same - it can only be worse!
95%

17. List two components of external failure.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Concluding there has been an effect/change when there has not.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
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

18. What is a run chart?
Outside.
Variable.
Mean time to failure.
A time series plot.

19. What are the four perspectives of the Balanced Scorecard?
Linearity - normality - homoscedasticity - independence.
Financial - customer - internal process - innovation and learning.
Assigns scores to weighted criteria for each project under consideration.
Scrap - rework - retest - downtime - yield losses - disposition costs.

20. In a regression - what does the standard error of the estimate tell you?
Linearity - normality - homoscedasticity - independence.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Concluding there has not been an effect/change when there has.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

21. What is DMADV?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Define - measure - analyze - design - verify.
A tool that shows performance along key dimensions all at once.
Through producer/consumer negotiation.

22. Define product reliability.
Mean time to failure.
A random variable that summarizes the information from the sample(s).
Large enough to find two of the attribute - on average.
The gap between what management thinks customers want and what customers really want.

23. What are the 5 Ss?
To do a capability study for a non-centered process.
The primary operating characteristics of a product.
Sort - Set in Order - Shine - Standardize - Sustain
The House of Quality.

24. If a Cp shows that a process is not capable - should you calculate Cpk?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Define - measure - analyze - improve - control.
Scrap - rework - retest - downtime - yield losses - disposition costs.
No -- if it is not the same - it can only be worse!

25. Design of Experiments (DOE) approach
Conformance to specifications.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Outside.
Represents the behavior of a process

26. What does Crosby say about benchmarking?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Causes that lead to a particular effect.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

27. What is Type 1 Error?
Concluding there has been an effect/change when there has not.
Linearity - normality - homoscedasticity - independence.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
=sqrt(Σ(x-x-bar)^2)/(n-1))

28. Name the structure associated with Quality Function Deployment.
95%
Mistake-proofing.
10 if Almost impossible to detect
The House of Quality.

29. What is a histogram?
Scrap - rework - retest - downtime - yield losses - disposition costs.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
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:
Speed - courtesy - competence - and ease of repair.

30. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
To manage the Six Sigma project.
It's good -- but it's still out of control!
They move closer to the center line.

31. What are the Five Dimensions of Service Quality?
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
Controlling quality at the source.
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:
Reliability - Assurance - Responsiveness - Tangibles - Empathy

32. What is a network diagram?
Lean (or JIT).
A diagram that shows the relationships between activities in a project network.
No -- the variation also has to be random and "expected."
Initiated before or at design concept finalization

33. Which type of SPC measurement is more precise - variable or attribute?
Lower skill requirements - faster - less chance for error.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Variable.
The degree to which a product meets pre-established standards.

34. When is Cpk used?
100%
To do a capability study for a non-centered process.
10 if Almost impossible to detect
If the Response vs. Levels graph if the response lines are not parallel (crossing)

35. What does the abbreviation UCL stand for?
Upper control limit.
Is what induces the failure
To monitor a process when measurement by variables is used.
Inventory = throughput x flow time.

36. Define durability.
Method developed by Ishikawa to graphically display the causes of any given problem
Lean (or JIT).
Is what induces the failure
Mean time to replacement.

37. What is a dashboard?
Conformance to specifications.
A tool that shows performance along key dimensions all at once.
Used to create frequency distribution tally sheets
Organize ideas into meaningful categories by recognizing their underlying similarity

38. List two components of prevention cost.
Pleasing to the senses.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Variable.
A diagram that shows the relationships between activities in a project network.

39. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Causes that lead to a particular effect.
Attribute
X-bar-bar

40. Process check sheets
Used to create frequency distribution tally sheets
To manage the Six Sigma project.
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.

41. Define performance quality.
The primary operating characteristics of a product.
QFD
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The ability of a process to consistently meet customer specifications.

42. What is a Gantt chart?
Not necessarily.
Is the way in which the failure is manifested.
Shows the temporal flow of activities in a project network.
Variable.

43. What is Kaizen?
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
Fishbone - cause-and-effect diagram.
To obtain a certain desirable outcome from the process
Rapid improvement process.

44. Define aesthetic quality.
Pleasing to the senses.
Someone who is consistently against virtually everything.
Large enough to find two of the attribute - on average.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

45. In a regression - what does the p value of F tell you?
Assigns scores to weighted criteria for each project under consideration.
Shifts - Trends - Repeating patterns - Correlation with known events
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 degree to which a product meets pre-established standards.

46. How are LQL and AQL determined in an acceptance sampling plan?
95%
Through producer/consumer negotiation.
Attribute.
The gap between what customers expect and the service they receive.

47. Your production process meets customer specifications. Is your process in control?
100%
Large enough to find two of the attribute - on average.
Not necessarily.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

48. Does it ever make sense to accept a job when a process is incapable?
Attribute
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Defects Per Million Opportunities
To manage the Six Sigma project.

49. FMEA
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
To monitor a process when measurement by attribute is used.
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
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

50. If you can only collect categorical data - what type of SPC charting can you do?
To monitor a process when measurement by attribute is used.
Attribute.
Concluding there has not been an effect/change when there has.
Lower control limit.