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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 does the abbreviation LCL stand for?
Outside.
X-bar-bar
Studying firms with the best performance in a particular area.
Lower control limit.

2. What type of risk is associated with Type II Error?
What the value of the dependent variable is when the independent variable is zero.
The target number of standard deviations from the mean for specifications.
Fewer good units to sell - increased variable cost/unit.
Consumer risk.

3. List Garvin's eight dimensions of product quality.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
The number of standard deviations some value is from the mean.
Blame.
Used to create frequency distribution tally sheets

4. With Six Sigma capability - how many defects per million opportunities would you see?
To be a member of a Six Sigma project team.
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).
3.4 (assuming 1.5 sigma shift in the mean)
Look for the assignable cause of non-random variation.

5. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
The gap between what management thinks customers want and what customers really want.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Outside.
Lean (or JIT).

6. Advantages of DOE
Rapid improvement 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
The number of standard deviations some value is from the mean.
Speed - courtesy - competence - and ease of repair.

7. Define perceived quality (Garvin's framework).
Rapid improvement process.
Brand image.
The gap between what is promised and what is delivered.
Failure Modes and Effects Analysis

8. What are two other names for an Ishikawa diagram?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
The gap between what customers expect and the service they receive.
Fishbone - cause-and-effect diagram.
Producer risk.

9. What is the role of a master black belt?
Organize ideas into meaningful categories by recognizing their underlying similarity
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
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
To mentor/coach (and sometimes train) black belts.

10. Daniel Test
The Japanese national quality award.
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:
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The ratio of outputs to inputs; 1-scrap.

11. In a regression - what does the p value of F tell you?
Brand image.
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).
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Variable.

12. What are the 5 Ss?
To do a capability study for a non-centered process.
The ratio of outputs to inputs; 1-scrap.
Sort - Set in Order - Shine - Standardize - Sustain
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).

13. If you can only collect categorical data - what type of SPC charting can you do?
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.
Look for the assignable cause of non-random variation.
A tool that shows performance along key dimensions all at once.
Attribute.

14. One factor at a time (OFAT)
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Walter A. Shewhart
To monitor a process when measurement by variables is used.
Hold all input variables constant except one. Observe the response as you vary the single input.

15. 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?
Lower skill requirements - faster - less chance for error.
Mistake-proofing.
Large enough to find two of the attribute - on average.
False - because each machine will have different natural tolerances.

16. How does Juran define quality?
68%
Organize ideas into meaningful categories by recognizing their underlying similarity
Attribute
Fitness for use.

17. Regression
To mentor/coach (and sometimes train) black belts.
A tool that shows where there is waste in a process.
Represents the behavior of a process
Workers - machines - materials.

18. Regression Analysis
Fitness for use.
The ability of a process to consistently meet customer specifications.
Waste.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

19. In the Service Quality Gap Model - what is Gap 1?
Blame.
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.
The gap between what management thinks customers want and what customers really want.

20. Process check sheets
X-bar-bar
The primary operating characteristics of a product.
Pleasing to the senses.
Used to create frequency distribution tally sheets

21. What is Little's Law?
Sampling for SPC is done real time.
Inventory = throughput x flow time.
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 scatterplot.

22. Who developed the fishbone diagram?
The gap between what management thinks customers want and the process specifications.
Kaoru Ishikawa.
A scatterplot.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

23. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
To monitor a process when measurement by variables is used.
The cycle time required to meet demand.
No -- the variation also has to be random and "expected."
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

24. TWO-DIMENTIONAL SCATTER PLOT
Inventory = throughput x flow time.
A diagram that shows the relationships between activities in a project network.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Fitness for use.

25. In the Service Quality Gap Model - what is Gap 4?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Through producer/consumer negotiation.
To manage the Six Sigma project.
The gap between what is promised and what is delivered.

26. What is poka yoke?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
50%
Defects Per Million Opportunities
Mistake-proofing.

27. What does Crosby say about benchmarking?
Mean time to failure.
Blame.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
To be a member of a Six Sigma project team.

28. 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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29. FMEA
Not necessarily.
Concluding there has not been an effect/change when there has.
A scatterplot.
It looks to minimize the probability of a failure - or to minimize its effects

30. What are the four regression assumptions?
The US national quality award.
Concluding there has been an effect/change when there has not.
Walter A. Shewhart
Linearity - normality - homoscedasticity - independence.

31. What is a Pareto chart?
3.4 (assuming 1.5 sigma shift in the mean)
A descending order-sorted bar chart with a cumulative percentage line.
They move closer to the center line.
To obtain a certain desirable outcome from the process

32. Uses of regression
=sqrt(Σ(x-x-bar)^2)/(n-1))
Lower control limit.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The target number of standard deviations from the mean for specifications.

33. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Technical quality is the "what" of the service; functional quality is the "how."
Lower control limit.
68%
Used to create frequency distribution tally sheets

34. Define performance quality.
The primary operating characteristics of a product.
10 if Almost impossible to detect
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Before production starts

35. If you have calculated a Cpk - should you also calculate a Cp?
Linearity - normality - homoscedasticity - independence.
Waste.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
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

36. Failure Mode
Scrap - rework - retest - downtime - yield losses - disposition costs.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Deming.
Is the way in which the failure is manifested.

37. What is process capability?
The manager in charge of a process being improved in a Six Sigma project.
The ability of a process to consistently meet customer specifications.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Actual drawings - layouts - maps - etc which show where a defect occurs

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

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39. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
Define - measure - analyze - improve - control.
The US national quality award.
Mean time to failure.

40. One factor at a time (OFAT)
= yij - y(bar)i --> value minus sum of that treatment (of row)
The gap between specifications and how service is performed.
To monitor a process when measurement by attribute is used.
Observed variation in response is caused by the input

41. What is a CAVE man?
Is the way in which the failure is manifested.
Someone who is consistently against virtually everything.
Consumer risk.
Large enough to find two of the attribute - on average.

42. Complete this quality phrase: 'Fix the process - not the _____.'
A brainstorming tool that shows the connections between ideas.
Blame.
To obtain a certain desirable outcome from the process
Producer risk.

43. In the Service Quality Gap Model - what is Gap 3?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Taguchi
The gap between specifications and how service is performed.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

44. What do you do when a process is out of control?
50%
Look for the assignable cause of non-random variation.
Represents the behavior of a process
Initiated before or at design concept finalization

45. The Test Statistic (TS)
A random variable that summarizes the information from the sample(s).
It's good -- but it's still out of control!
Upper control limit.
Shows the temporal flow of activities in a project network.

46. Risk Priority Number RPN
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Initiated before or at design concept finalization
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
Actual drawings - layouts - maps - etc which show where a defect occurs

47. Define benchmarking.
The gap between specifications and how service is performed.
Studying firms with the best performance in a particular area.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Lean (or JIT).

48. Detection Criteria Ranking
Someone who is consistently against virtually everything.
Upper control limit.
10 if Almost impossible to detect
Reliability - Assurance - Responsiveness - Tangibles - Empathy

49. What quality tool formally incorporates the voice of the customer?
Linearity - normality - homoscedasticity - independence.
Someone who is consistently against virtually everything.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
QFD

50. Disadvantages of DOE

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