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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?
The House of Quality.
Define - measure - analyze - design - verify.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
A diagram that shows the relationships between activities in a project network.

2. What is the role of a black belt?
Not necessarily.
Observed variation in response is caused by the input
Concluding there has not been an effect/change when there has.
To manage the Six Sigma project.

3. What do you do when a process is out of control?
An assertion or conjecture concerning one or more populations
Look for the assignable cause of non-random variation.
Mean time to replacement.
Lean is waste reduction - Six Sigma is variation reduction.

4. Based on what principal can we use the normal distribution assumptions for SPC?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Central Limit Theorem
Define - measure - analyze - improve - control.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

5. FMEA
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
p-bar - the long-run percent defective.
It looks to minimize the probability of a failure - or to minimize its effects
5%

6. Definition of Interaction
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
To monitor a process when measurement by attribute is used.
Pleasing to the senses.
Sort - Set in Order - Shine - Standardize - Sustain

7. In the Service Quality Gap Model - what is Gap 5?
A tool that shows where there is waste in a process.
Central Limit Theorem
The gap between what customers expect and the service they receive.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

8. List two components of internal failure.
The ability of a process to consistently meet customer specifications.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Lower control limit.
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

9. DOE
The gap between what management thinks customers want and the process specifications.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Supplier - input - process - output - customer.

10. Uses of regression - Control
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Mean time to replacement.
To obtain a certain desirable outcome from the process
Consumer risk.

11. Does it ever make sense to accept a job when a process is incapable?
Define - measure - analyze - design - verify.
Attribute.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
The gap between what is promised and what is delivered.

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

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13. What quality guru emphasizes management as a system?
Kaoru Ishikawa.
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
Speed - courtesy - competence - and ease of repair.
Deming.

14. Which type of SPC measurement is more precise - variable or attribute?
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 brainstorming tool that shows the connections between ideas.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Variable.

15. What type of risk is associated with Type II Error?
Consumer risk.
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 brainstorming tool that shows the connections between ideas.
The gap between what management thinks customers want and what customers really want.

16. In the Service Quality Gap Model - what is Gap 4?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Used to create frequency distribution tally sheets
The gap between what is promised and what is delivered.
Is what induces the failure

17. Risk Priority Number RPN
If the Response vs. Levels graph if the response lines are not parallel (crossing)
QFD
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
A tool that shows where there is waste in a process.

18. Test for Independence
They move closer to the center line.
Through producer/consumer negotiation.
50%
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

19. Histogram by Hand
They move closer to the center line.
Prevention and appraisal costs are balanced against internal and external failure.
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
The gap between what customers expect and the service they receive.

20. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
To monitor a process when measurement by variables is used.
99.73%
To obtain a certain desirable outcome from the process
A diagram that shows the relationships between activities in a project network.

21. Define takt time.
The cycle time required to meet demand.
Before production starts
Define - measure - analyze - design - verify.
95%

22. 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
p-bar - the long-run percent defective.
Lean is waste reduction - Six Sigma is variation reduction.
A descending order-sorted bar chart with a cumulative percentage line.

23. In a regression - what does the standard error of the estimate tell you?
No -- if it is not the same - it can only be worse!
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The gap between what is promised and what is delivered.
What the value of the dependent variable is when the independent variable is zero.

24. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Used to create frequency distribution tally sheets
Fishbone - cause-and-effect diagram.
To obtain a certain desirable outcome from the process
Sampling for SPC is done real time.

25. What does Crosby say about benchmarking?
A brainstorming tool that shows the connections between ideas.
50%
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A time series plot.

26. Complete this quality phrase: 'Fix the process - not the _____.'
Blame.
Organize ideas into meaningful categories by recognizing their underlying similarity
Method developed by Ishikawa to graphically display the causes of any given problem
Initiated before or at design concept finalization

27. What is a Gage R&R?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
To mentor/coach (and sometimes train) black belts.
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).
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

28. What is written on the "spines" of a fishbone diagram?
The House of Quality.
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).
Look for the assignable cause of non-random variation.
Causes that lead to a particular effect.

29. Detection Criteria Ranking
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
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).
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
10 if Almost impossible to detect

30. F value
Represents the behavior of a process
Mean time to replacement.
Someone who is consistently against virtually everything.
F_alpha - df(tr) - df (error)

31. What does the abbreviation LCL stand for?
Is the consequence of the failure.
Lower control limit.
Causes that lead to a particular effect.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

32. What quality tool formally incorporates the voice of the customer?
QFD
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Technical quality is the "what" of the service; functional quality is the "how."
Prevention - appraisal - internal failure - external failure.

33. What are the four categories of costs in Juran's framework?
Prevention - appraisal - internal failure - external failure.
Lean (or JIT).
A random variable that summarizes the information from the sample(s).
The gap between specifications and how service is performed.

34. What is the role of a master black belt?
What the value of the dependent variable is when the independent variable is zero.
To mentor/coach (and sometimes train) black belts.
Attribute.
Define - measure - analyze - improve - control.

35. Uses of regression
Can't tell without a Range chart.
The gap between what management thinks customers want and what customers really want.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
100%

36. With Six Sigma capability - how many defects per million opportunities would you see?
3.4 (assuming 1.5 sigma shift in 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
Look for the assignable cause of non-random variation.
Causes that lead to a particular effect.

37. What is Type 1 Error?
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).
Concluding there has been an effect/change when there has not.
Is what induces the failure

38. What is a Pareto chart?
Brand image.
A descending order-sorted bar chart with a cumulative percentage line.
Critical to quality.
Represents the behavior of a process

39. Define performance quality.
Lower control limit.
50%
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
The primary operating characteristics of a product.

40. Define perceived quality (Garvin's framework).
Consumer risk.
Different types of defects are listed (used for Pareto chart)
Brand image.
Workers - machines - materials.

41. List two components of prevention cost.
False - because each machine will have different natural tolerances.
Sampling for SPC is done real time.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Scrap - rework - retest - downtime - yield losses - disposition costs.

42. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
No -- only if the process is also capable.
The gap between what customers expect and the service they receive.
The number of standard deviations some value is from the mean.

43. What is a spaghetti diagram?
Not necessarily.
Linearity - normality - homoscedasticity - independence.
Conformance to specifications.
A tool that shows the physical flows through a space.

44. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
To be a member of a Six Sigma project team.
5%
Lower skill requirements - faster - less chance for error.

45. Taguchi's experimental designs are of this type.
Hold all input variables constant except one. Observe the response as you vary the single input.
Fractional factorial designs (orthogonal arrays)
The gap between what customers expect and the service they receive.
Lower skill requirements - faster - less chance for error.

46. Failure effect
Causes that lead to a particular effect.
Is the consequence of the failure.
F_alpha - df(tr) - df (error)
Concluding there has been an effect/change when there has not.

47. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Attribute
Before production starts
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Producer risk.

48. Regression
Mean time to replacement.
Represents the behavior of a process
Kaoru Ishikawa.
Define - measure - analyze - design - verify.

49. What does DMAIC stand for?
Controlling quality at the source.
Define - measure - analyze - improve - control.
What the value of the dependent variable is when the independent variable is zero.
Concluding there has not been an effect/change when there has.

50. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
Large enough to find two of the attribute - on average.
Not necessarily.
3.4 (assuming 1.5 sigma shift in the mean)