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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 is the formula for standard deviation?
=sqrt(Σ(x-x-bar)^2)/(n-1))
Blame.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The ratio of outputs to inputs; 1-scrap.

2. What quality tool formally incorporates the voice of the customer?
Concluding there has been an effect/change when there has not.
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
QFD
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).

3. If you can only collect categorical data - what type of SPC charting can you do?
A diagram that shows the relationships between activities in a project network.
Attribute.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Fishbone - cause-and-effect diagram.

4. In the Service Quality Gap Model - what is Gap 1?
The gap between what management thinks customers want and what customers really want.
No -- the variation also has to be random and "expected."
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 process of ranking opportunities to determine which of many potential opportunities should be pursued first.

5. Manual Test for Nomality
Initiated before or at design concept finalization
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Attribute.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

6. Who is a process owner?
X-bar-bar
Rapid improvement 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.
The manager in charge of a process being improved in a Six Sigma project.

7. Define perceived quality (Garvin's framework).
Workers - machines - materials.
Brand image.
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).
Lean is waste reduction - Six Sigma is variation reduction.

8. Failure Mode
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Stratify a particular defect type according to logical criteria
To be a member of a Six Sigma project team.
Is the way in which the failure is manifested.

9. What is the difference between Lean and Six Sigma?
Lean is waste reduction - Six Sigma is variation reduction.
A diagram that shows the relationships between activities in a project network.
Is the way in which the failure is manifested.
Prevention and appraisal costs are balanced against internal and external failure.

10. What is CTQ?
A diagram that shows the relationships between activities in a project network.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Critical to quality.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

11. When yields decrease - what are the two effects on contribution?
10 for Hazardous without warning 1 for none
Inventory = throughput x flow time.
To mentor/coach (and sometimes train) black belts.
Fewer good units to sell - increased variable cost/unit.

12. In a Z table - what is Z?
The number of standard deviations some value is from the mean.
Because the mean and standard deviation are independent of each other.
Critical to quality.
No -- the variation also has to be random and "expected."

13. In the Service Quality Gap Model - what is Gap 4?
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 gap between what is promised and what is delivered.
Outside.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

14. What is Type II Error?
Variable.
Prevention and appraisal costs are balanced against internal and external failure.
Concluding there has not been an effect/change when there has.
Actual drawings - layouts - maps - etc which show where a defect occurs

15. What is the center line of an X-bar chart?
Variable.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
X-bar-bar
68%

16. What is the 5S model?
No -- only if the process is also capable.
Financial - customer - internal process - innovation and learning.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

17. What is the Deming Prize?
Through producer/consumer negotiation.
The Japanese national quality award.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Variable.

18. Explain the difference between technical and functional service quality.
Concluding there has not been an effect/change when there has.
Technical quality is the "what" of the service; functional quality is the "how."
To manage the Six Sigma project.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

19. What quality guru emphasizes management as a system?
Attribute
Deming.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The House of Quality.

20. What happens to control limits on an SPC chart when sample size is increased?
They move closer to the center line.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Attribute.
The gap between what customers expect and the service they receive.

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

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22. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Walter A. Shewhart
Prevention and appraisal costs are balanced against internal and external failure.
False - because each machine will have different natural tolerances.
Outside.

23. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
The ability of a process to consistently meet customer specifications.
F_alpha - df(tr) - df (error)
To do a capability study for a non-centered process.
Lean (or JIT).

24. What is a Pareto chart?
Blame.
A descending order-sorted bar chart with a cumulative percentage line.
It's good -- but it's still out of control!
Workers - machines - materials.

25. Detection Criteria Ranking
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Represents the behavior of a process
Define - measure - analyze - design - verify.
10 if Almost impossible to detect

26. What is the center line of a p-chart?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
p-bar - the long-run percent defective.
Concluding there has been an effect/change when there has not.

27. In the Service Quality Gap Model - what is Gap 2?
Is the consequence of the failure.
The gap between what management thinks customers want and the process specifications.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Prevention and appraisal costs are balanced against internal and external failure.

28. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
To be a member of a Six Sigma project team.
Kaoru Ishikawa.
They move closer to the center line.
95%

29. DOE
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 Almost impossible to detect
Failure Modes and Effects Analysis
Someone who is consistently against virtually everything.

30. What are two other names for an Ishikawa diagram?
Fishbone - cause-and-effect diagram.
Consumer risk.
It's good -- but it's still out of 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

31. What is a Gage R&R?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
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).
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Central Limit Theorem

32. Disadvantages of DOE

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33. Creating a Run Chart
Is what induces the failure
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
5%
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

34. Residual(eij)
= yij - y(bar)i --> value minus sum of that treatment (of row)
= 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
Outside.
Supplier - input - process - output - customer.

35. What is poka yoke?
Through producer/consumer negotiation.
Mistake-proofing.
Fitness for use.
To manage the Six Sigma project.

36. A process is operating "in control." Does this mean the customer's requirements are met?
No -- only if the process is also capable.
It's good -- but it's still out of control!
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
5%

37. Defect location check sheets
10 if Almost impossible to detect
F_alpha - df(tr) - df (error)
Brand image.
Actual drawings - layouts - maps - etc which show where a defect occurs

38. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Deming.
Consumer risk.
No -- the variation also has to be random and "expected."

39. PFMEA
68%
Speed - courtesy - competence - and ease of repair.
Before production starts
A tool that shows performance along key dimensions all at once.

40. One factor at a time (OFAT)
Is the way in which the failure is manifested.
Observed variation in response is caused by the input
The House of Quality.
Inventory = throughput x flow time.

41. Non-random patterns (Run Charts)
The gap between what customers expect and the service they receive.
Shifts - Trends - Repeating patterns - Correlation with known events
Deming.
Conformance to specifications.

42. What do you do when a process is out of control?
The manager in charge of a process being improved in a Six Sigma project.
Look for the assignable cause of non-random variation.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
The House of Quality.

43. If a three-stage process has 90% yields at each stage - what is the overall yield?
Attribute
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
0.9^3 or 72.9%
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

44. Daniel Test
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 Japanese national quality award.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Scrap - rework - retest - downtime - yield losses - disposition costs.

45. What are the four perspectives of the Balanced Scorecard?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A random variable that summarizes the information from the sample(s).
Financial - customer - internal process - innovation and learning.
p-bar - the long-run percent defective.

46. In a regression - what does the standard error of the estimate tell you?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
10 if Almost impossible to detect
Failure Modes and Effects Analysis
Outside.

47. Design of Experiments (DOE) approach
The gap between what customers expect and the service they receive.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Large enough to find two of the attribute - on average.
The secondary characteristics of a product; "bells and whistles."

48. How are LQL and AQL determined in an acceptance sampling plan?
Fractional factorial designs (orthogonal arrays)
The US national quality award.
99.73%
Through producer/consumer negotiation.

49. Define benchmarking.
Studying firms with the best performance in a particular area.
To monitor a process when measurement by variables is used.
Prevention and appraisal costs are balanced against internal and external failure.
50%

50. In the Service Quality Gap Model - what is Gap 5?
Taguchi
=sqrt(Σ(x-x-bar)^2)/(n-1))
Causes that lead to a particular effect.
The gap between what customers expect and the service they receive.