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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 a network diagram?
Rapid improvement process.
A diagram that shows the relationships between activities in a project network.
The secondary characteristics of a product; "bells and whistles."
The gap between what management thinks customers want and what customers really want.

2. Taguchi's experimental designs are of this type.
5%
Concluding there has not been an effect/change when there has.
Fractional factorial designs (orthogonal arrays)
The US national quality award.

3. Does it ever make sense to accept a job when a process is incapable?
The US national quality award.
The Japanese national quality award.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
The gap between specifications and how service is performed.

4. Failure effect
Speed - courtesy - competence - and ease of repair.
A brainstorming tool that shows the connections between ideas.
Is the consequence of the failure.
Lean (or JIT).

5. What are the Five Dimensions of Service Quality?
0.9^3 or 72.9%
Reliability - Assurance - Responsiveness - Tangibles - Empathy
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
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).

6. What quality guru emphasizes management as a system?
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:
Deming.
Observed variation in response is caused by the input
The gap between what management thinks customers want and what customers really want.

7. Process occurance ranking
Central Limit Theorem
F_alpha - df(tr) - df (error)
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
To monitor a process when measurement by variables is used.

8. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Assigns scores to weighted criteria for each project under consideration.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Conformance to specifications.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

9. If you can only collect categorical data - what type of SPC charting can you do?
Attribute.
Attribute
It looks to minimize the probability of a failure - or to minimize its effects
Mistake-proofing.

10. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
= yij - y(bar)i --> value minus sum of that treatment (of row)
QFD
68%
The House of Quality.

11. What is CTQ?
The ability of a process to consistently meet customer specifications.
To manage the Six Sigma project.
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.

12. What type of risk is associated with Type 1 Error?
Producer risk.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
X-bar-bar

13. What is FMEA?
Failure Modes and Effects Analysis
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
The ability of a process to consistently meet customer specifications.
68%

14. Failure Mode
Assigns scores to weighted criteria for each project under consideration.
No -- the variation also has to be random and "expected."
Prevention and appraisal costs are balanced against internal and external failure.
Is the way in which the failure is manifested.

15. What type of risk is associated with Type II Error?
Consumer risk.
Can't tell without a Range chart.
Walter A. Shewhart
p-bar - the long-run percent defective.

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

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17. In a regression - what does R-square tell you?
Studying firms with the best performance in a particular area.
Initiated before or at design concept finalization
Workers - machines - materials.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

18. Define takt time.
Scrap - rework - retest - downtime - yield losses - disposition costs.
The cycle time required to meet demand.
Lower skill requirements - faster - less chance for error.
Fractional factorial designs (orthogonal arrays)

19. Define product reliability.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Mean time to failure.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

20. Effect ranking (Severity of the Defect)
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
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
10 for Hazardous without warning 1 for none
QFD

21. Who first studied randomness in industrial processes
Walter A. Shewhart
The gap between what customers expect and the service they receive.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Shifts - Trends - Repeating patterns - Correlation with known events

22. PFMEA
Fishbone - cause-and-effect diagram.
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
Is what induces the failure

23. Define benchmarking.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
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
Studying firms with the best performance in a particular area.
A descending order-sorted bar chart with a cumulative percentage line.

24. Non-random patterns (Run Charts)
To do a capability study for a non-centered 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
A random variable that summarizes the information from the sample(s).
Shifts - Trends - Repeating patterns - Correlation with known events

25. What is Jidoka?
Controlling quality at the source.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
To monitor a process when measurement by attribute is used.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

26. Defect check sheets
Someone who is consistently against virtually everything.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
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
Different types of defects are listed (used for Pareto chart)

27. Complete this quality phrase: 'Fix the process - not the _____.'
= yij - y(bar)i --> value minus sum of that treatment (of row)
Blame.
Lower skill requirements - faster - less chance for error.
The gap between what management thinks customers want and the process specifications.

28. Test for Independence
No -- only if the process is also capable.
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
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Define - measure - analyze - improve - control.

29. In the Service Quality Gap Model - what is Gap 1?
Supplier - input - process - output - customer.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Is the consequence of the failure.
The gap between what management thinks customers want and what customers really want.

30. How does Juran define quality?
To obtain a certain desirable outcome from the process
Fitness for use.
Scrap - rework - retest - downtime - yield losses - disposition costs.
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)
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
Studying firms with the best performance in a particular area.
Observed variation in response is caused by the input
Sort - Set in Order - Shine - Standardize - Sustain

32. In the Service Quality Gap Model - what is Gap 3?
The gap between what customers expect and the service they receive.
The gap between specifications and how service is performed.
Outside.
Variable.

33. Define performance quality.
The primary operating characteristics of a product.
Shifts - Trends - Repeating patterns - Correlation with known events
Outside.
Sort - Set in Order - Shine - Standardize - Sustain

34. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Kaoru Ishikawa.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Outside.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

35. What is Type 1 Error?
Define - measure - analyze - improve - control.
Fewer good units to sell - increased variable cost/unit.
Concluding there has been an effect/change when there has not.
QFD

36. Presence of interaction effect
Blame.
What the value of the dependent variable is when the independent variable is zero.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Mean time to replacement.

37. How are LQL and AQL determined in an acceptance sampling plan?
Prevention and appraisal costs are balanced against internal and external failure.
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.
Pleasing to the senses.
Through producer/consumer negotiation.

38. In a regression - what does the standard error of the estimate tell you?
Critical to quality.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

39. Define durability.
Fractional factorial designs (orthogonal arrays)
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Mean time to replacement.
p-bar - the long-run percent defective.

40. List two components of prevention cost.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
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
Method developed by Ishikawa to graphically display the causes of any given problem
Financial - customer - internal process - innovation and learning.

41. What is the role of a master black belt?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
The US national quality award.
To mentor/coach (and sometimes train) black belts.
X-bar-bar

42. What does Crosby say about benchmarking?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
To manage the Six Sigma project.
X-bar-bar

43. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Attribute
The target number of standard deviations from the mean for specifications.
0.9^3 or 72.9%
Variable.

44. For what is a p-chart used?
To monitor a process when measurement by attribute is used.
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
0.9^3 or 72.9%
5%

45. 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?
Concluding there has not been an effect/change when there has.
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).
False - because each machine will have different natural tolerances.
Attribute

46. What is the role of a black belt?
To mentor/coach (and sometimes train) black belts.
Before production starts
Mean time to replacement.
To manage the Six Sigma project.

47. What percentage of a normal distribution lies above 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
50%
Is the consequence of the failure.
Central Limit Theorem

48. Stratified defect check sheets
Stratify a particular defect type according to logical criteria
Attribute.
Define - measure - analyze - improve - control.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

49. Who is a process owner?
Actual drawings - layouts - maps - etc which show where a defect occurs
The ability of a process to consistently meet customer specifications.
Producer risk.
The manager in charge of a process being improved in a Six Sigma project.

50. Define perceived quality (Garvin's framework).
Mistake-proofing.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Brand image.
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: