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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. Effect ranking (Severity of the Defect)
10 for Hazardous without warning 1 for none
To be a member of a Six Sigma project team.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
The cycle time required to meet demand.

2. What does the abbreviation UCL stand for?
Variable.
Upper control limit.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
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

3. Cause and Effect Diagrams
A descending order-sorted bar chart with a cumulative percentage line.
Prevention and appraisal costs are balanced against internal and external failure.
Consumer risk.
Method developed by Ishikawa to graphically display the causes of any given problem

4. What does Crosby say about benchmarking?
Financial - customer - internal process - innovation and learning.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Sampling for SPC is done real time.
3.4 (assuming 1.5 sigma shift in the mean)

5. What is the formula for the standard deviation of a proportion?
5%
=sqrt((p*(1-p)/n)
=sqrt(Σ(x-x-bar)^2)/(n-1))
Actual drawings - layouts - maps - etc which show where a defect occurs

6. What is a network diagram?
Assigns scores to weighted criteria for each project under consideration.
Studying firms with the best performance in a particular area.
To do a capability study for a non-centered process.
A diagram that shows the relationships between activities in a project network.

7. F value
They move closer to the center line.
Through producer/consumer negotiation.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
F_alpha - df(tr) - df (error)

8. What is the Baldrige Award?
Sort - Set in Order - Shine - Standardize - Sustain
The US national quality award.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Critical to quality.

9. When is Cpk 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
To do a capability study for a non-centered process.
Sampling for SPC is done real time.
Supplier - input - process - output - customer.

10. 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
To do a capability study for a non-centered process.
Initiated before or at design concept finalization
Lower control limit.

11. Regression
Before production starts
= yij - y(bar)i --> value minus sum of that treatment (of row)
A diagram that shows the relationships between activities in a project network.
Represents the behavior of a process

12. What is written on the "spines" of a fishbone diagram?
Causes that lead to a particular effect.
The gap between what management thinks customers want and what customers really want.
The primary operating characteristics of a product.
Failure Modes and Effects Analysis

13. Presence of interaction effect
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Different types of defects are listed (used for Pareto chart)
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

14. What is a dashboard?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Concluding there has not been an effect/change when there has.
Is the way in which the failure is manifested.
A tool that shows performance along key dimensions all at once.

15. Taguchi's experimental designs are of this type.
To mentor/coach (and sometimes train) black belts.
Upper control limit.
The degree to which a product meets pre-established standards.
Fractional factorial designs (orthogonal arrays)

16. What size should samples be for attribute SPC?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Shifts - Trends - Repeating patterns - Correlation with known events
Large enough to find two of the attribute - on average.
95%

17. Daniel Test
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).
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:
The ability of a process to consistently meet customer specifications.
Kaoru Ishikawa.

18. If a three-stage process has 90% yields at each stage - what is the overall yield?
The gap between what management thinks customers want and the process specifications.
Stratify a particular defect type according to logical criteria
0.9^3 or 72.9%
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

19. 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?
Kaoru Ishikawa.
False - because each machine will have different natural tolerances.
A tool that shows the physical flows through a space.
Financial - customer - internal process - innovation and learning.

20. Test for Independence
100%
The gap between what customers expect and the service they receive.
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
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

21. With Six Sigma capability - how many defects per million opportunities would you see?
The degree to which a product meets pre-established standards.
To mentor/coach (and sometimes train) black belts.
95%
3.4 (assuming 1.5 sigma shift in the mean)

22. PFMEA
Rapid improvement process.
The number of standard deviations some value is from the mean.
Before production starts
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

23. Which quality guru developed the concept of loss to society?
Before production starts
A scatterplot.
Variable.
Taguchi

24. Based on what principal can we use the normal distribution assumptions for SPC?
Technical quality is the "what" of the service; functional quality is the "how."
Central Limit Theorem
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
A random variable that summarizes the information from the sample(s).

25. What are the 5 Ss?
Observed variation in response is caused by the input
A time series plot.
Sort - Set in Order - Shine - Standardize - Sustain
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

26. Pareto Analysis
Brand image.
No -- only if the process is also capable.
The cycle time required to meet demand.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

27. Who first studied randomness in industrial processes
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Walter A. Shewhart
No -- only if the process is also capable.
Shifts - Trends - Repeating patterns - Correlation with known events

28. Disadvantages of DOE

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29. What percentage of a normal distribution lies above the mean?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Concluding there has not been an effect/change when there has.
50%
Organize ideas into meaningful categories by recognizing their underlying similarity

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

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31. In a Z table - what is Z?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The number of standard deviations some value is from the mean.
Assigns scores to weighted criteria for each project under consideration.
No -- only if the process is also capable.

32. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Studying firms with the best performance in a particular area.
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).
5%
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

33. What is muda
Is what induces the failure
95%
68%
Waste.

34. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
Fishbone - cause-and-effect diagram.
p-bar - the long-run percent defective.
Variable.

35. What is a histogram?
Prevention - appraisal - internal failure - external failure.
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
Waste.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

36. What is poka yoke?
=sqrt(Σ(x-x-bar)^2)/(n-1))
Fractional factorial designs (orthogonal arrays)
Mistake-proofing.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

37. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
A tool that shows where there is waste in a process.
Supplier - input - process - output - customer.
Lower skill requirements - faster - less chance for error.

38. List two components of internal failure.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Scrap - rework - retest - downtime - yield losses - disposition costs.

39. FMEA
Inventory = throughput x flow time.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
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
10 for Hazardous without warning 1 for none

40. Define benchmarking.
Blame.
The manager in charge of a process being improved in a Six Sigma project.
Studying firms with the best performance in a particular area.
Concluding there has been an effect/change when there has not.

41. What is Type 1 Error?
Attribute
Prevention - appraisal - internal failure - external failure.
Fewer good units to sell - increased variable cost/unit.
Concluding there has been an effect/change when there has not.

42. Failure effect
The US national quality award.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Controlling quality at the source.
Is the consequence of the failure.

43. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
0.9^3 or 72.9%
Critical to quality.
Conformance to specifications.
Stratify a particular defect type according to logical criteria

44. What is DPMO?
Defects Per Million Opportunities
Mistake-proofing.
Is what induces the failure
A time series plot.

45. Definition of Interaction
To obtain a certain desirable outcome from the process
Financial - customer - internal process - innovation and learning.
Organize ideas into meaningful categories by recognizing their underlying similarity
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

46. If a Cp shows that a process is not capable - should you calculate Cpk?
Is the consequence of the failure.
No -- if it is not the same - it can only be worse!
= 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
Sampling for SPC is done real time.

47. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Variable.
The Japanese national quality award.
Can't tell without a Range chart.
99.73%

48. When yields decrease - what are the two effects on contribution?
No -- if it is not the same - it can only be worse!
Can't tell without a Range chart.
Variable.
Fewer good units to sell - increased variable cost/unit.

49. What is the difference between Lean and Six Sigma?
To do a capability study for a non-centered process.
A time series plot.
Lean is waste reduction - Six Sigma is variation reduction.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

50. Uses of regression - Control
The manager in charge of a process being improved in a Six Sigma project.
Concluding there has not been an effect/change when there has.
Concluding there has been an effect/change when there has not.
To obtain a certain desirable outcome from the process