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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 type of risk is associated with Type 1 Error?
Different types of defects are listed (used for Pareto chart)
Producer risk.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Concluding there has not been an effect/change when there has.

2. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
The target number of standard deviations from the mean for specifications.
95%
10 if Almost impossible to detect
5%

3. Process occurance ranking
Concluding there has been an effect/change when there has not.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Sort - Set in Order - Shine - Standardize - Sustain
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

4. In a regression - what does the coefficient of the intercept tell you
95%
What the value of the dependent variable is when the independent variable is zero.
A tool that shows where there is waste in a process.
Supplier - input - process - output - customer.

5. Defect check sheets
Different types of defects are listed (used for Pareto chart)
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).
Organize ideas into meaningful categories by recognizing their underlying similarity
To do a capability study for a non-centered process.

6. 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
Variable.
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
Mean time to replacement.

7. 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?
Method developed by Ishikawa to graphically display the causes of any given problem
3.4 (assuming 1.5 sigma shift in the mean)
False - because each machine will have different natural tolerances.
They move closer to the center line.

8. What is the difference between Lean and Six Sigma?
An assertion or conjecture concerning one or more populations
Mean time to replacement.
Lean is waste reduction - Six Sigma is variation reduction.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

9. Define product reliability.
The US national quality award.
Sort - Set in Order - Shine - Standardize - Sustain
Kaoru Ishikawa.
Mean time to failure.

10. Process check sheets
Causes that lead to a particular effect.
Used to create frequency distribution tally sheets
=sqrt(Σ(x-x-bar)^2)/(n-1))
It's good -- but it's still out of control!

11. Which quality guru developed the concept of loss to society?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
The US national quality award.
To do a capability study for a non-centered process.
Taguchi

12. What does a project prioritization matrix do?
Failure Modes and Effects Analysis
Assigns scores to weighted criteria for each project under consideration.
Is the way in which the failure is manifested.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

13. 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.
Variable.
0.9^3 or 72.9%

14. Define performance quality.
Lean (or JIT).
Is the way in which the failure is manifested.
The primary operating characteristics of a product.
Waste.

15. What does Crosby say about benchmarking?
The primary operating characteristics of a product.
Shows the temporal flow of activities in a project network.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Large enough to find two of the attribute - on average.

16. In a regression - what does R-square tell you?
Define - measure - analyze - design - verify.
Hold all input variables constant except one. Observe the response as you vary the single input.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

17. What is the Deming Prize?
The Japanese national quality award.
Define - measure - analyze - improve - control.
The gap between what customers expect and the service they receive.
Prevention - appraisal - internal failure - external failure.

18. In a Z table - what is Z?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
A tool that shows where there is waste in a process.
A tool that shows performance along key dimensions all at once.
The number of standard deviations some value is from the mean.

19. Risk Priority Number RPN
Define - measure - analyze - improve - control.
Consumer risk.
Observed variation in response is caused by the input
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

20. If a three-stage process has 90% yields at each stage - what is the overall yield?
A brainstorming tool that shows the connections between ideas.
Rapid improvement process.
0.9^3 or 72.9%
p-bar - the long-run percent defective.

21. In the Service Quality Gap Model - what is Gap 3?
They move closer to the center line.
The gap between specifications and how service is performed.
To manage the Six Sigma project.
The secondary characteristics of a product; "bells and whistles."

22. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
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
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:
68%
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

23. What is a run chart?
Look for the assignable cause of non-random variation.
A time series plot.
To monitor a process when measurement by variables is used.
The target number of standard deviations from the mean for specifications.

24. Name the structure associated with Quality Function Deployment.
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.
Large enough to find two of the attribute - on average.
The House of Quality.

25. What is the role of a black belt?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
No -- only if the process is also capable.
To manage the Six Sigma project.
Fishbone - cause-and-effect diagram.

26. 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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27. Failure effect
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Is the consequence of the failure.
Critical to quality.
Workers - machines - materials.

28. Define aesthetic quality.
Pleasing to the senses.
No -- if it is not the same - it can only be worse!
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.

29. Define conformance quality.
Supplier - input - process - output - customer.
= 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
The degree to which a product meets pre-established standards.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

30. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Mean time to replacement.
Lean (or JIT).
To monitor a process when measurement by variables is used.

31. Definition of Interaction
Large enough to find two of the attribute - on average.
The gap between what management thinks customers want and what customers really want.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Failure Modes and Effects Analysis

32. What is a Pareto chart?
They move closer to the center line.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Attribute
A descending order-sorted bar chart with a cumulative percentage line.

33. Which type of SPC measurement is more precise - variable or attribute?
The gap between what management thinks customers want and the process specifications.
Through producer/consumer negotiation.
Variable.
The Japanese national quality award.

34. What does DMAIC stand for?
Can't tell without a Range chart.
The degree to which a product meets pre-established standards.
=sqrt((p*(1-p)/n)
Define - measure - analyze - improve - control.

35. Failure Mode
Lean is waste reduction - Six Sigma is variation reduction.
Kaoru Ishikawa.
The gap between specifications and how service is performed.
Is the way in which the failure is manifested.

36. What is the center line of an X-bar chart?
Sort - Set in Order - Shine - Standardize - Sustain
99.73%
Attribute
X-bar-bar

37. What is a histogram?
The gap between what customers expect and the service they receive.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
To manage the Six Sigma project.
Attribute

38. What is Jidoka?
Central Limit Theorem
Controlling quality at the source.
Attribute.
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:

39. What is the formula for standard deviation?
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
=sqrt(Σ(x-x-bar)^2)/(n-1))
10 if Almost impossible to detect
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

40. Based on what principal can we use the normal distribution assumptions for SPC?
Brand image.
Financial - customer - internal process - innovation and learning.
3.4 (assuming 1.5 sigma shift in the mean)
Central Limit Theorem

41. Affinity Diagrams
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Prevention and appraisal costs are balanced against internal and external failure.
Stratify a particular defect type according to logical criteria
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

42. Failure cause
Is what induces the failure
The degree to which a product meets pre-established standards.
Conformance to specifications.
Blame.

43. When yields decrease - what are the two effects on contribution?
Hold all input variables constant except one. Observe the response as you vary the single input.
Fewer good units to sell - increased variable cost/unit.
X-bar-bar
Controlling quality at the source.

44. Regression Analysis
p-bar - the long-run percent defective.
5%
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Define - measure - analyze - design - verify.

45. What does SIPOC stand for?
A tool that shows the physical flows through a space.
Supplier - input - process - output - customer.
Workers - machines - materials.
Mean time to replacement.

46. Does it ever make sense to accept a job when a process is incapable?
To obtain a certain desirable outcome from the process
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
To mentor/coach (and sometimes train) black belts.
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

47. One factor at a time (OFAT)
50%
Is what induces the failure
Hold all input variables constant except one. Observe the response as you vary the single input.
Fractional factorial designs (orthogonal arrays)

48. Residual
Pleasing to the senses.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

49. What is Little's Law?
Inventory = throughput x flow time.
Critical to quality.
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
Sampling for SPC is done real time.

50. In a regression - what does the standard error of the estimate tell you?
It looks to minimize the probability of a failure - or to minimize its effects
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Hold all input variables constant except one. Observe the response as you vary the single input.
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: