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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. In a regression - what does R-square tell you?
Waste.
Concluding there has not been an effect/change when there has.
95%
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

2. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Defects Per Million Opportunities
Prevention and appraisal costs are balanced against internal and external failure.

3. Uses of regression - Control
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
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).
To obtain a certain desirable outcome from the process
Taguchi

4. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Rapid improvement process.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Lower skill requirements - faster - less chance for error.
Hold all input variables constant except one. Observe the response as you vary the single input.

5. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
The House of Quality.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Consumer risk.

6. When is Cpk used?
A random variable that summarizes the information from the sample(s).
The manager in charge of a process being improved in a Six Sigma project.
Assigns scores to weighted criteria for each project under consideration.
To do a capability study for a non-centered process.

7. If a Cp shows that a process is not capable - should you calculate Cpk?
Mean time to replacement.
False - because each machine will have different natural tolerances.
= 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
No -- if it is not the same - it can only be worse!

8. Non-random patterns (Run Charts)
It's good -- but it's still out of control!
Shifts - Trends - Repeating patterns - Correlation with known events
Look for the assignable cause of non-random variation.
Prevention and appraisal costs are balanced against internal and external failure.

9. What is the role of a master black belt?
To mentor/coach (and sometimes train) black belts.
To be a member of a Six Sigma project team.
The ability of a process to consistently meet customer specifications.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

10. 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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11. FMEA
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 gap between what customers expect and the service they receive.
False - because each machine will have different natural tolerances.
Conformance to specifications.

12. What does the abbreviation LCL stand for?
Lower control limit.
Attribute
10 for Hazardous without warning 1 for none
Speed - courtesy - competence - and ease of repair.

13. What is a Gage R&R?
Initiated before or at design concept finalization
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
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).

14. List two appraisal costs.
A brainstorming tool that shows the connections between ideas.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
A time series plot.
Causes that lead to a particular effect.

15. Explain the difference between technical and functional service quality.
Observed variation in response is caused by the input
It's good -- but it's still out of control!
Can't tell without a Range chart.
Technical quality is the "what" of the service; functional quality is the "how."

16. Define yield.
The ratio of outputs to inputs; 1-scrap.
Brand image.
95%
50%

17. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
It's good -- but it's still out of control!
Waste.
To do a capability study for a non-centered process.

18. What is the center line of a p-chart?
p-bar - the long-run percent defective.
Sampling for SPC is done real time.
The number of standard deviations some value is from the mean.
No -- the variation also has to be random and "expected."

19. DFMEA
The target number of standard deviations from the mean for specifications.
Used to create frequency distribution tally sheets
68%
Initiated before or at design concept finalization

20. 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."
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Because the mean and standard deviation are independent of each other.
Variable.

21. In the Service Quality Gap Model - what is Gap 1?
A descending order-sorted bar chart with a cumulative percentage line.
The gap between what management thinks customers want and what customers really want.
68%
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

22. Who developed the fishbone diagram?
3.4 (assuming 1.5 sigma shift in the mean)
Kaoru Ishikawa.
Method developed by Ishikawa to graphically display the causes of any given problem
Shifts - Trends - Repeating patterns - Correlation with known events

23. Failure cause
Conformance to specifications.
They move closer to the center line.
A random variable that summarizes the information from the sample(s).
Is what induces the failure

24. Define product reliability.
No -- if it is not the same - it can only be worse!
Mean time to failure.
Different types of defects are listed (used for Pareto chart)
Attribute.

25. Affinity Diagrams
Pleasing to the senses.
The secondary characteristics of a product; "bells and whistles."
Organize ideas into meaningful categories by recognizing their underlying similarity
50%

26. Test for constant variance
Someone who is consistently against virtually everything.
The number of standard deviations some value is from the mean.
To do a capability study for a non-centered process.
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.

27. Define conformance quality.
The gap between what is promised and what is delivered.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
The degree to which a product meets pre-established standards.
To mentor/coach (and sometimes train) black belts.

28. PFMEA
Before production starts
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Through producer/consumer negotiation.
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

29. What does SIPOC stand for?
95%
Supplier - input - process - output - customer.
The target number of standard deviations from the mean for specifications.
The gap between what customers expect and the service they receive.

30. What is Type II Error?
Concluding there has not been an effect/change when there has.
10 if Almost impossible to detect
No -- only if the process is also capable.
Observed variation in response is caused by the input

31. What is written on the "spines" of a fishbone diagram?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Taguchi
Causes that lead to a particular effect.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

32. Define aesthetic quality.
Pleasing to the senses.
A diagram that shows the relationships between activities in a project network.
It looks to minimize the probability of a failure - or to minimize its effects
They move closer to the center line.

33. Manual Test for Nomality
They move closer to the center line.
= yij - y(bar)i --> value minus sum of that treatment (of row)
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
=sqrt(Σ(x-x-bar)^2)/(n-1))

34. List two components of prevention cost.
It looks to minimize the probability of a failure - or to minimize its effects
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
To mentor/coach (and sometimes train) black belts.
= yij - y(bar)i --> value minus sum of that treatment (of row)

35. What is a Pareto chart?
Look for the assignable cause of non-random variation.
To monitor a process when measurement by variables is used.
Workers - machines - materials.
A descending order-sorted bar chart with a cumulative percentage line.

36. What is a run chart?
Someone who is consistently against virtually everything.
A time series plot.
Studying firms with the best performance in a particular area.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

37. What are the four categories of costs in Juran's framework?
No -- if it is not the same - it can only be worse!
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.
Prevention - appraisal - internal failure - external failure.
Lean (or JIT).

38. What is a Gantt chart?
The gap between what management thinks customers want and what customers really want.
Shows the temporal flow of activities in a project network.
68%
The gap between what customers expect and the service they receive.

39. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
A tool that shows the physical flows through a space.
Outside.
To monitor a process when measurement by variables is used.
The House of Quality.

40. 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
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).
The gap between specifications and how service is performed.
Define - measure - analyze - improve - control.

41. What happens to control limits on an SPC chart when sample size is increased?
Causes that lead to a particular effect.
A scatterplot.
They move closer to the center line.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

42. What are two other names for an Ishikawa diagram?
No -- only if the process is also capable.
Fishbone - cause-and-effect diagram.
The US national quality award.
Because the mean and standard deviation are independent of each other.

43. What is the Deming Prize?
The primary operating characteristics of a product.
To monitor a process when measurement by attribute is used.
Technical quality is the "what" of the service; functional quality is the "how."
The Japanese national quality award.

44. What is Little's Law?
Linearity - normality - homoscedasticity - independence.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Inventory = throughput x flow time.
Mean time to failure.

45. Residual(eij)
Causes that lead to a particular effect.
p-bar - the long-run percent defective.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
= yij - y(bar)i --> value minus sum of that treatment (of row)

46. What is FMEA?
The gap between what customers expect and the service they receive.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
False - because each machine will have different natural tolerances.
Failure Modes and Effects Analysis

47. What is Type 1 Error?
Concluding there has been an effect/change when there has not.
Lower control limit.
It looks to minimize the probability of a failure - or to minimize its effects
The degree to which a product meets pre-established standards.

48. What is the difference between the way sampling is done for SPC and for acceptance sampling?
A diagram that shows the relationships between activities in a project network.
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.
Defects Per Million Opportunities

49. In the Service Quality Gap Model - what is Gap 4?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Not necessarily.
To manage the Six Sigma project.
The gap between what is promised and what is delivered.

50. What quality tool formally incorporates the voice of the customer?
Workers - machines - materials.
5%
=sqrt((p*(1-p)/n)
QFD