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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?
=sqrt((p*(1-p)/n)
A diagram that shows the relationships between activities in a project network.
False - because each machine will have different natural tolerances.
Organize ideas into meaningful categories by recognizing their underlying similarity

2. When is Cpk used?
The target number of standard deviations from the mean for specifications.
To do a capability study for a non-centered process.
Financial - customer - internal process - innovation and learning.
To be a member of a Six Sigma project team.

3. Design of Experiments (DOE) approach
Assigns scores to weighted criteria for each project under consideration.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The primary operating characteristics of a product.
Different types of defects are listed (used for Pareto chart)

4. Cause and Effect Diagrams
Different types of defects are listed (used for Pareto chart)
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:
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Method developed by Ishikawa to graphically display the causes of any given problem

5. Risk Priority Number RPN
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Is the consequence of the failure.
A brainstorming tool that shows the connections between ideas.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

6. Manual Test for Nomality
The gap between what management thinks customers want and what customers really want.
A time series plot.
Is the way in which the failure is manifested.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

7. Who is a process owner?
Lean is waste reduction - Six Sigma is variation reduction.
A diagram that shows the relationships between activities in a project network.
Represents the behavior of a process
The manager in charge of a process being improved in a Six Sigma project.

8. In a regression - what does R-square tell you?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
=sqrt(Σ(x-x-bar)^2)/(n-1))
= yij - y(bar)i --> value minus sum of that treatment (of row)
Taguchi

9. If you can only collect categorical data - what type of SPC charting can you do?
10 for Hazardous without warning 1 for none
Attribute.
No -- if it is not the same - it can only be worse!
3.4 (assuming 1.5 sigma shift in the mean)

10. Name the structure associated with Quality Function Deployment.
p-bar - the long-run percent defective.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
The House of Quality.
No -- only if the process is also capable.

11. Taguchi's experimental designs are of this type.
Fractional factorial designs (orthogonal arrays)
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Failure Modes and Effects Analysis
50%

12. A process is operating "in control." Does this mean the customer's requirements are met?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
No -- only if the process is also capable.
Kaoru Ishikawa.
Mistake-proofing.

13. Creating a Run Chart
No -- only if the process is also capable.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Used to create frequency distribution tally sheets
Failure Modes and Effects Analysis

14. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Sampling for SPC is done real time.
Fitness for use.
Critical to quality.
Shifts - Trends - Repeating patterns - Correlation with known events

15. Effect ranking (Severity of the Defect)
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
To obtain a certain desirable outcome from the process
10 for Hazardous without warning 1 for none
Sampling for SPC is done real time.

16. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Organize ideas into meaningful categories by recognizing their underlying similarity
Outside.
68%
99.73%

17. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
Used to create frequency distribution tally sheets
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
To be a member of a Six Sigma project team.

18. Define features.
The secondary characteristics of a product; "bells and whistles."
Kaoru Ishikawa.
Is the consequence of the failure.
Mean time to replacement.

19. What is the role of a green belt?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Define - measure - analyze - design - verify.
Prevention and appraisal costs are balanced against internal and external failure.
To be a member of a Six Sigma project team.

20. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
The target number of standard deviations from the mean for specifications.
Walter A. Shewhart
99.73%
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

21. Failure Mode
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
A tool that shows where there is waste in a process.
Is the way in which the failure is manifested.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

22. Your production process meets customer specifications. Is your process in control?
What the value of the dependent variable is when the independent variable is zero.
Is what induces the failure
Not necessarily.
The US national quality award.

23. Regression Analysis
Speed - courtesy - competence - and ease of repair.
Prevention and appraisal costs are balanced against internal and external failure.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Used to create frequency distribution tally sheets

24. What is the formula for the standard deviation of a proportion?
F_alpha - df(tr) - df (error)
What the value of the dependent variable is when the independent variable is zero.
=sqrt((p*(1-p)/n)
Method developed by Ishikawa to graphically display the causes of any given problem

25. 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
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Fractional factorial designs (orthogonal arrays)
Lean (or JIT).

26. Process check sheets
Used to create frequency distribution tally sheets
Before production starts
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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

27. What is the role of a black belt?
To manage the Six Sigma project.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Fishbone - cause-and-effect diagram.
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).

28. FMEA
It looks to minimize the probability of a failure - or to minimize its effects
No -- only if the process is also capable.
Concluding there has not been an effect/change when there has.
10 for Hazardous without warning 1 for none

29. If you have calculated a Cpk - should you also calculate a Cp?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Stratify a particular defect type according to logical criteria
5%
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

30. You have been plotting sample means on an x-bar chart and all points indicate normal - expected variation. Is the process in control?

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31. What is CTQ?
Concluding there has been an effect/change when there has not.
=sqrt((p*(1-p)/n)
Critical to quality.
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

32. Process occurance ranking
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

33. Residual(eij)
Large enough to find two of the attribute - on average.
No -- if it is not the same - it can only be worse!
= 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

34. If a Cp shows that a process is not capable - should you calculate Cpk?
It's good -- but it's still out of control!
Assigns scores to weighted criteria for each project under consideration.
A brainstorming tool that shows the connections between ideas.
No -- if it is not the same - it can only be worse!

35. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
False - because each machine will have different natural tolerances.
Fishbone - cause-and-effect diagram.
Attribute
The number of standard deviations some value is from the mean.

36. What is an affinity diagram?
A brainstorming tool that shows the connections between ideas.
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
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

37. With Six Sigma capability - how many defects per million opportunities would you see?
3.4 (assuming 1.5 sigma shift in the mean)
99.73%
Shows the temporal flow of activities in a project network.
The gap between specifications and how service is performed.

38. What is poka yoke?
Lean is waste reduction - Six Sigma is variation reduction.
The US national quality award.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Mistake-proofing.

39. What is the 5S model?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Observed variation in response is caused by the input
The secondary characteristics of a product; "bells and whistles."
Supplier - input - process - output - customer.

40. Defect location check sheets
Actual drawings - layouts - maps - etc which show where a defect occurs
= yij - y(bar)i --> value minus sum of that treatment (of row)
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.
Speed - courtesy - competence - and ease of repair.

41. What are two other names for an Ishikawa diagram?
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
Speed - courtesy - competence - and ease of repair.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Fishbone - cause-and-effect diagram.

42. What is DMADV?
10 if Almost impossible to detect
Define - measure - analyze - design - verify.
Hold all input variables constant except one. Observe the response as you vary the single input.
The degree to which a product meets pre-established standards.

43. What graphical tool is used to show the relationship between two numerical variables?
Look for the assignable cause of non-random variation.
No -- the variation also has to be random and "expected."
Attribute.
A scatterplot.

44. Define durability.
Through producer/consumer negotiation.
Defects Per Million Opportunities
Method developed by Ishikawa to graphically display the causes of any given problem
Mean time to replacement.

45. When yields decrease - what are the two effects on contribution?
The ratio of outputs to inputs; 1-scrap.
Fewer good units to sell - increased variable cost/unit.
Fishbone - cause-and-effect diagram.
Shifts - Trends - Repeating patterns - Correlation with known events

46. Why do you need two control charts for variables SPC?
10 if Almost impossible to detect
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).
Because the mean and standard deviation are independent of each other.
Financial - customer - internal process - innovation and learning.

47. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
95%
Large enough to find two of the attribute - on average.
F_alpha - df(tr) - df (error)

48. Which quality guru developed the concept of loss to society?
Upper control limit.
Look for the assignable cause of non-random variation.
Shows the temporal flow of activities in a project network.
Taguchi

49. What does Crosby say about benchmarking?
Large enough to find two of the attribute - on average.
Look for the assignable cause of non-random variation.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Studying firms with the best performance in a particular area.

50. Explain the difference between technical and functional service quality.
A descending order-sorted bar chart with a cumulative percentage line.
Technical quality is the "what" of the service; functional quality is the "how."
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Attribute.