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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 the coefficient of the intercept tell you
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
What the value of the dependent variable is when the independent variable is zero.
Outside.
The ability of a process to consistently meet customer specifications.

2. What is the role of a black belt?
Concluding there has not been an effect/change when there has.
Through producer/consumer negotiation.
Conformance to specifications.
To manage the Six Sigma project.

3. List two components of internal failure.
No -- only if the process is also capable.
Speed - courtesy - competence - and ease of repair.
Scrap - rework - retest - downtime - yield losses - disposition costs.
To mentor/coach (and sometimes train) black belts.

4. Define product reliability.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Mean time to failure.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
To monitor a process when measurement by variables is used.

5. Who first studied randomness in industrial processes
Lean (or JIT).
Walter A. Shewhart
Kaoru Ishikawa.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

6. PFMEA
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Before production starts
Deming.

7. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Variable.
Can't tell without a Range chart.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
10 if Almost impossible to detect

8. F value
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Lean is waste reduction - Six Sigma is variation reduction.
F_alpha - df(tr) - df (error)
Not necessarily.

9. What are the four categories of costs in Juran's framework?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
50%
Prevention - appraisal - internal failure - external failure.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

10. If a three-stage process has 90% yields at each stage - what is the overall yield?
Is the consequence of the failure.
0.9^3 or 72.9%
The gap between specifications and how service is performed.
Workers - machines - materials.

11. Simple Regression Analysis (one factor regression model)
= 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
A scatterplot.
Someone who is consistently against virtually everything.
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

12. What is a Gage R&R?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
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.
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).
They move closer to the center line.

13. Define serviceability.
Speed - courtesy - competence - and ease of repair.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
To monitor a process when measurement by variables is used.
Defects Per Million Opportunities

14. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Lean is waste reduction - Six Sigma is variation reduction.
Lower skill requirements - faster - less chance for error.
0.9^3 or 72.9%
Walter A. Shewhart

15. What is FMEA?
Fractional factorial designs (orthogonal arrays)
Fitness for use.
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
Failure Modes and Effects Analysis

16. Definition of Interaction
Lean is waste reduction - Six Sigma is variation reduction.
Causes that lead to a particular effect.
Someone who is consistently against virtually everything.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

17. A process is operating "in control." Does this mean the customer's requirements are met?
Outside.
Is what induces the failure
The gap between what management thinks customers want and the process specifications.
No -- only if the process is also capable.

18. What percentage of a normal distribution lies above the mean?
The ratio of outputs to inputs; 1-scrap.
Large enough to find two of the attribute - on average.
50%
A tool that shows performance along key dimensions all at once.

19. In the Service Quality Gap Model - what is Gap 1?
The gap between what management thinks customers want and what customers really want.
The gap between what management thinks customers want and the process specifications.
No -- the variation also has to be random and "expected."
Kaoru Ishikawa.

20. In the Service Quality Gap Model - what is Gap 4?
Is the consequence of the 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).
The gap between what is promised and what is delivered.
A tool that shows performance along key dimensions all at once.

21. FMEA
The gap between what is promised and what is delivered.
Attribute
Shows the temporal flow of activities in a project network.
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

22. Affinity Diagrams
Kaoru Ishikawa.
Organize ideas into meaningful categories by recognizing their underlying similarity
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
5%

23. One factor at a time (OFAT)
Represents the behavior of a process
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Observed variation in response is caused by the input
Concluding there has been an effect/change when there has not.

24. In a Z table - what is Z?
The House of Quality.
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).
Large enough to find two of the attribute - on average.
The number of standard deviations some value is from the mean.

25. What is the Deming Prize?
Defects Per Million Opportunities
Pleasing to the senses.
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.
The Japanese national quality award.

26. Design of Experiments (DOE) approach
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Causes that lead to a particular effect.
Fewer good units to sell - increased variable cost/unit.
No -- if it is not the same - it can only be worse!

27. Defect check sheets
Different types of defects are listed (used for Pareto chart)
The House of Quality.
It looks to minimize the probability of a failure - or to minimize its effects
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

28. Stratified defect check sheets
Fewer good units to sell - increased variable cost/unit.
Stratify a particular defect type according to logical criteria
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
Used to create frequency distribution tally sheets

29. Failure cause
Is what induces the failure
Kaoru Ishikawa.
A time series plot.
99.73%

30. Taguchi's experimental designs are of this type.
Fractional factorial designs (orthogonal arrays)
The secondary characteristics of a product; "bells and whistles."
QFD
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

31. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Mean time to replacement.
A brainstorming tool that shows the connections between ideas.

32. Failure Mode
Lean (or JIT).
F_alpha - df(tr) - df (error)
The Japanese national quality award.
Is the way in which the failure is manifested.

33. Risk Priority Number RPN
Outside.
Speed - courtesy - competence - and ease of repair.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
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

34. When is Cpk used?
= 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
Speed - courtesy - competence - and ease of repair.
To do a capability study for a non-centered process.
Concluding there has not been an effect/change when there has.

35. Disadvantages of DOE

36. What is the role of a green belt?
Mean time to replacement.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Lower skill requirements - faster - less chance for error.
To be a member of a Six Sigma project team.

37. Affinity Diagrams
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
Because the mean and standard deviation are independent of each other.
Observed variation in response is caused by the input

38. TWO-DIMENTIONAL SCATTER PLOT
Is the consequence of the failure.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Stratify a particular defect type according to logical criteria
Prevention and appraisal costs are balanced against internal and external failure.

39. What is a Pareto chart?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Upper control limit.
A descending order-sorted bar chart with a cumulative percentage line.
Shifts - Trends - Repeating patterns - Correlation with known events

40. Define performance 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
Initiated before or at design concept finalization
3.4 (assuming 1.5 sigma shift in the mean)
The primary operating characteristics of a product.

41. Process occurance ranking
Lean is waste reduction - Six Sigma is variation reduction.
Defects Per Million Opportunities
Through producer/consumer negotiation.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

42. In a regression - what does R-square tell you?
Linearity - normality - homoscedasticity - independence.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
It's good -- but it's still out of control!
Stratify a particular defect type according to logical criteria

43. What is an affinity diagram?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Critical to quality.
A brainstorming tool that shows the connections between ideas.
Mistake-proofing.

44. Defect location check sheets
Prevention and appraisal costs are balanced against internal and external failure.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Fewer good units to sell - increased variable cost/unit.
Actual drawings - layouts - maps - etc which show where a defect occurs

45. Regression Analysis
The gap between what customers expect and the service they receive.
To manage the Six Sigma project.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
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

46. What is CTQ?
Hold all input variables constant except one. Observe the response as you vary the single input.
Critical to quality.
Different types of defects are listed (used for Pareto chart)
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

47. What is the 5S model?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Failure Modes and Effects Analysis
A tool that shows where there is waste in a process.
The gap between what management thinks customers want and the process specifications.

48. What are two other names for an Ishikawa diagram?
Consumer risk.
Fishbone - cause-and-effect diagram.
50%
Mistake-proofing.

49. Which quality guru developed the concept of loss to society?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Taguchi
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.

50. Residual(eij)
= yij - y(bar)i --> value minus sum of that treatment (of row)
A scatterplot.
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 gap between what customers expect and the service they receive.