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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. If a three-stage process has 90% yields at each stage - what is the overall yield?
Variable.
Can't tell without a Range chart.
Is what induces the failure
0.9^3 or 72.9%

2. DFMEA
Initiated before or at design concept finalization
Mistake-proofing.
It looks to minimize the probability of a failure - or to minimize its effects
The gap between what customers expect and the service they receive.

3. What is the role of a green belt?
Fewer good units to sell - increased variable cost/unit.
5%
To be a member of a Six Sigma project team.
Causes that lead to a particular effect.

4. What happens to control limits on an SPC chart when sample size is increased?
Linearity - normality - homoscedasticity - independence.
Financial - customer - internal process - innovation and learning.
Outside.
They move closer to the center line.

5. What does SIPOC stand for?
Kaoru Ishikawa.
Supplier - input - process - output - customer.
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
3.4 (assuming 1.5 sigma shift in the mean)

6. What is the formula for standard deviation?
The number of standard deviations some value is from the mean.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Through producer/consumer negotiation.
99.73%

7. Presence of interaction effect
False - because each machine will have different natural tolerances.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Workers - machines - materials.
Attribute.

8. What does Crosby say about benchmarking?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Defects Per Million Opportunities
A time series plot.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

9. List two appraisal costs.
No -- the variation also has to be random and "expected."
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Is the consequence of the failure.

10. What is poka yoke?
The Japanese national quality award.
They move closer to the center line.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Mistake-proofing.

11. How does Juran define quality?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Fitness for use.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Large enough to find two of the attribute - on average.

12. Define takt time.
Scrap - rework - retest - downtime - yield losses - disposition costs.
The cycle time required to meet demand.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
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

13. A process is operating "in control." Does this mean the customer's requirements are met?
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The target number of standard deviations from the mean for specifications.
No -- only if the process is also capable.
A random variable that summarizes the information from the sample(s).

14. What is the Baldrige Award?
The US national quality award.
Prevention - appraisal - internal failure - external failure.
Lean is waste reduction - Six Sigma is variation reduction.
Defects Per Million Opportunities

15. In a regression - what does the p value of F tell you?
The secondary characteristics of a product; "bells and whistles."
The gap between what is promised and what is delivered.
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 degree to which a product meets pre-established standards.

16. What is the center line of an X-bar chart?
A scatterplot.
Actual drawings - layouts - maps - etc which show where a defect occurs
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
X-bar-bar

17. Define conformance quality.
The degree to which a product meets pre-established standards.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
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
Method developed by Ishikawa to graphically display the causes of any given problem

18. When is Cpk used?
0.9^3 or 72.9%
Deming.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
To do a capability study for a non-centered process.

19. In the Service Quality Gap Model - what is Gap 1?
The gap between specifications and how service is performed.
The gap between what management thinks customers want and what customers really want.
Prevention and appraisal costs are balanced against internal and external failure.
To do a capability study for a non-centered process.

20. Uses of regression
95%
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Conformance to specifications.
= 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

21. Process occurance ranking
Large enough to find two of the attribute - on average.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
False - because each machine will have different natural tolerances.
Causes that lead to a particular effect.

22. Failure effect
Is the consequence of the failure.
An assertion or conjecture concerning one or more populations
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Taguchi

23. Non-random patterns (Run Charts)
Deming.
=sqrt((p*(1-p)/n)
F_alpha - df(tr) - df (error)
Shifts - Trends - Repeating patterns - Correlation with known events

24. What graphical tool is used to show the relationship between two numerical variables?
Brand image.
Mean time to failure.
A scatterplot.
Large enough to find two of the attribute - on average.

25. In the Service Quality Gap Model - what is Gap 2?
Define - measure - analyze - design - verify.
The gap between what management thinks customers want and the process specifications.
10 if Almost impossible to detect
To be a member of a Six Sigma project team.

26. TWO-DIMENTIONAL SCATTER PLOT
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
The secondary characteristics of a product; "bells and whistles."
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
Sampling for SPC is done real time.

27. What is FMEA?
Lean (or JIT).
Failure Modes and Effects Analysis
The ratio of outputs to inputs; 1-scrap.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

28. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
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
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
95%

29. Residual(eij)
= yij - y(bar)i --> value minus sum of that treatment (of row)
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
To monitor a process when measurement by attribute is used.
Linearity - normality - homoscedasticity - independence.

30. If you can only collect categorical data - what type of SPC charting can you do?
= yij - y(bar)i --> value minus sum of that treatment (of row)
Fewer good units to sell - increased variable cost/unit.
Attribute.
Walter A. Shewhart

31. List two components of external failure.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
A tool that shows performance along key dimensions all at once.
Large enough to find two of the attribute - on average.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

32. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
Initiated before or at design concept finalization
Producer risk.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

33. In the Service Quality Gap Model - what is Gap 5?
The gap between what customers expect and the service they receive.
Large enough to find two of the attribute - on average.
A tool that shows where there is waste in a process.
The secondary characteristics of a product; "bells and whistles."

34. Define product reliability.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Mean time to failure.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
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).

35. What type of risk is associated with Type 1 Error?
Someone who is consistently against virtually everything.
False - because each machine will have different natural tolerances.
Before production starts
Producer risk.

36. What are the four regression assumptions?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
No -- if it is not the same - it can only be worse!
p-bar - the long-run percent defective.
Linearity - normality - homoscedasticity - independence.

37. FMEA
10 for Hazardous without warning 1 for none
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
The gap between what is promised and what is delivered.
5%

38. Explain the difference between technical and functional service quality.
Different types of defects are listed (used for Pareto chart)
Technical quality is the "what" of the service; functional quality is the "how."
Initiated before or at design concept finalization
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

39. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
=sqrt((p*(1-p)/n)
No -- the variation also has to be random and "expected."
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

40. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
No -- the variation also has to be random and "expected."
Taguchi
Fishbone - cause-and-effect diagram.
Is the consequence of the failure.

41. Who first studied randomness in industrial processes
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
Walter A. Shewhart
An assertion or conjecture concerning one or more populations
Stratify a particular defect type according to logical criteria

42. Creating a Run Chart
The manager in charge of a process being improved in a Six Sigma project.
No -- only if the process is also capable.
The degree to which a product meets pre-established standards.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

43. Disadvantages of DOE

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44. Advantages of DOE
QFD
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
Define - measure - analyze - design - verify.
Defects Per Million Opportunities

45. In the Service Quality Gap Model - what is Gap 4?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Financial - customer - internal process - innovation and learning.
The gap between what is promised and what is delivered.
50%

46. What is a Pareto chart?
A tool that shows performance along key dimensions all at once.
A descending order-sorted bar chart with a cumulative percentage line.
Variable.
Because the mean and standard deviation are independent of each other.

47. Define perceived quality (Garvin's framework).
Brand image.
Blame.
0.9^3 or 72.9%
The degree to which a product meets pre-established standards.

48. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
The gap between what management thinks customers want and what customers really want.
100%
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
X-bar-bar

49. What quality tool formally incorporates the voice of the customer?
A diagram that shows the relationships between activities in a project network.
Used to create frequency distribution tally sheets
QFD
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

50. When yields decrease - what are the two effects on contribution?
Fewer good units to sell - increased variable cost/unit.
Upper control limit.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.