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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 Type 1 Error?
Define - measure - analyze - improve - control.
Concluding there has been an effect/change when there has not.
Is the way in which the failure is manifested.
Look for the assignable cause of non-random variation.

2. Define conformance quality.
The degree to which a product meets pre-established standards.
The gap between what management thinks customers want and the process specifications.
Lower control limit.
Pleasing to the senses.

3. What are the four categories of costs in Juran's framework?
Prevention - appraisal - internal failure - external failure.
Is the way in which the failure is manifested.
Not necessarily.
To manage the Six Sigma project.

4. Explain the difference between technical and functional service quality.
Is what induces the failure
Technical quality is the "what" of the service; functional quality is the "how."
= 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
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

5. Complete this quality phrase: 'Fix the process - not the _____.'
The ability of a process to consistently meet customer specifications.
Blame.
Stratify a particular defect type according to logical criteria
Supplier - input - process - output - customer.

6. One factor at a time (OFAT)
Observed variation in response is caused by the input
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Deming.
The cycle time required to meet demand.

7. Define aesthetic quality.
Pleasing to the senses.
Prevention - appraisal - internal failure - external failure.
A scatterplot.
A diagram that shows the relationships between activities in a project network.

8. Failure cause
Workers - machines - materials.
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.
Large enough to find two of the attribute - on average.
Is what induces the failure

9. What is a CAVE man?
Someone who is consistently against virtually everything.
A diagram that shows the relationships between activities in a project network.
The gap between what is promised and what is delivered.
Concluding there has been an effect/change when there has not.

10. List two components of prevention cost.
Fractional factorial designs (orthogonal arrays)
=sqrt((p*(1-p)/n)
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:
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

11. List two appraisal costs.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Failure Modes and Effects Analysis
Walter A. Shewhart
To monitor a process when measurement by attribute is used.

12. If you have calculated a Cpk - should you also calculate a Cp?
Lower control limit.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

13. What does Crosby say about benchmarking?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Scrap - rework - retest - downtime - yield losses - disposition costs.
The ability of a process to consistently meet customer specifications.
Lean is waste reduction - Six Sigma is variation reduction.

14. What is Type II Error?
Concluding there has not been an effect/change when there has.
Is the way in which the failure is manifested.
3.4 (assuming 1.5 sigma shift in the mean)
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

15. Regression
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
They move closer to the center line.
A brainstorming tool that shows the connections between ideas.
Represents the behavior of a process

16. Detection Criteria Ranking
10 if Almost impossible to detect
Brand image.
A brainstorming tool that shows the connections between ideas.
F_alpha - df(tr) - df (error)

17. Effect ranking (Severity of the Defect)
10 for Hazardous without warning 1 for none
=sqrt((p*(1-p)/n)
Is what induces the failure
Stratify a particular defect type according to logical criteria

18. Define product reliability.
Used to create frequency distribution tally sheets
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Mean time to failure.
Mean time to replacement.

19. What is Value Stream Mapping?
A time series plot.
Initiated before or at design concept finalization
A brainstorming tool that shows the connections between ideas.
A tool that shows where there is waste in a process.

20. Define durability.
Different types of defects are listed (used for Pareto chart)
Observed variation in response is caused by the input
A tool that shows performance along key dimensions all at once.
Mean time to replacement.

21. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
Initiated before or at design concept finalization
No -- if it is not the same - it can only be worse!
Not necessarily.

22. What quality guru emphasizes management as a system?
They move closer to the center line.
Hold all input variables constant except one. Observe the response as you vary the single input.
Deming.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

23. What are the four perspectives of the Balanced Scorecard?
Financial - customer - internal process - innovation and learning.
Mistake-proofing.
Sampling for SPC is done real time.
Supplier - input - process - output - customer.

24. Define features.
5%
A descending order-sorted bar chart with a cumulative percentage line.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The secondary characteristics of a product; "bells and whistles."

25. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Fishbone - cause-and-effect diagram.
Prevention and appraisal costs are balanced against internal and external failure.
A diagram that shows the relationships between activities in a project network.
Initiated before or at design concept finalization

26. Define serviceability.
Shows the temporal flow of activities in a project network.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Speed - courtesy - competence - and ease of repair.
The degree to which a product meets pre-established standards.

27. What is muda
Waste.
Upper control limit.
Actual drawings - layouts - maps - etc which show where a defect occurs
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:

28. With Six Sigma capability - how many defects per million opportunities would you see?
Fractional factorial designs (orthogonal arrays)
To monitor a process when measurement by attribute is used.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
3.4 (assuming 1.5 sigma shift in the mean)

29. The Test Statistic (TS)
An assertion or conjecture concerning one or more populations
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Financial - customer - internal process - innovation and learning.
A random variable that summarizes the information from the sample(s).

30. Test for Independence
Shows the temporal flow of activities in a project network.
The Japanese national quality award.
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
The degree to which a product meets pre-established standards.

31. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
68%
Different types of defects are listed (used for Pareto chart)
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

32. In the Service Quality Gap Model - what is Gap 4?
Sort - Set in Order - Shine - Standardize - Sustain
The gap between what is promised and what is delivered.
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
Someone who is consistently against virtually everything.

33. Test for constant variance
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
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.
Variable.
Prevention - appraisal - internal failure - external failure.

34. What is Jidoka?
=sqrt(Σ(x-x-bar)^2)/(n-1))
The ratio of outputs to inputs; 1-scrap.
Controlling quality at the source.
3.4 (assuming 1.5 sigma shift in the mean)

35. What is the role of a green belt?
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:
To be a member of a Six Sigma project team.
The gap between specifications and how service is performed.
Supplier - input - process - output - customer.

36. What type of risk is associated with Type 1 Error?
Producer risk.
Organize ideas into meaningful categories by recognizing their underlying similarity
What the value of the dependent variable is when the independent variable is zero.
Deming.

37. What is a Gage R&R?
Pleasing to the senses.
A tool that shows the physical flows through a space.
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).
False - because each machine will have different natural tolerances.

38. What is the formula for standard deviation?
Lower control limit.
A tool that shows where there is waste in a process.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Fractional factorial designs (orthogonal arrays)

39. DFMEA
99.73%
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Initiated before or at design concept finalization
Not necessarily.

40. PFMEA
Financial - customer - internal process - innovation and learning.
Before production starts
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).
50%

41. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
Is the consequence of the failure.
The gap between what is promised and what is delivered.
To manage the Six Sigma project.

42. Process occurance ranking
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
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
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
99.73%

43. Taguchi's experimental designs are of this type.
Represents the behavior of a process
Fractional factorial designs (orthogonal arrays)
No -- only if the process is also capable.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

44. One factor at a time (OFAT)
The ability of a process to consistently meet customer specifications.
= yij - y(bar)i --> value minus sum of that treatment (of row)
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Hold all input variables constant except one. Observe the response as you vary the single input.

45. In a regression - what does the standard error of the estimate tell you?
Shows the temporal flow of activities in a project network.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Conformance to specifications.
Studying firms with the best performance in a particular area.

46. What is the role of a black belt?
=sqrt((p*(1-p)/n)
Shows the temporal flow of activities in a project network.
To manage the Six Sigma project.
Kaoru Ishikawa.

47. Defect location check sheets
Upper control limit.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Actual drawings - layouts - maps - etc which show where a defect occurs
Producer risk.

48. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
The gap between what is promised and what is delivered.
Conformance to specifications.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Fishbone - cause-and-effect diagram.

49. In a regression - what does R-square tell you?
Lean is waste reduction - Six Sigma is variation reduction.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
The gap between what management thinks customers want and what customers really want.

50. Residual
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The House of Quality.
Lean is waste reduction - Six Sigma is variation reduction.
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.