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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 run chart?
A scatterplot.
A time series plot.
Failure Modes and Effects Analysis
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

2. Why do you need two control charts for variables SPC?
Causes that lead to a particular effect.
Because the mean and standard deviation are independent of each other.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Studying firms with the best performance in a particular area.

3. DOE
= yij - y(bar)i --> value minus sum of that treatment (of row)
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
They move closer to the center line.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

4. In a regression - what does the p value of F tell you?
Hold all input variables constant except one. Observe the response as you vary the single input.
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).
Assigns scores to weighted criteria for each project under consideration.
Fractional factorial designs (orthogonal arrays)

5. What is the role of a black belt?
Define - measure - analyze - improve - control.
Fishbone - cause-and-effect diagram.
To manage the Six Sigma project.
Not necessarily.

6. What graphical tool is used to show the relationship between two numerical variables?
Central Limit Theorem
A scatterplot.
A tool that shows the physical flows through a space.
50%

7. Non-random patterns (Run Charts)
10 if Almost impossible to detect
Initiated before or at design concept finalization
Mean time to failure.
Shifts - Trends - Repeating patterns - Correlation with known events

8. In a Z table - what is Z?
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 number of standard deviations some value is from the mean.
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
What the value of the dependent variable is when the independent variable is zero.

9. TWO-DIMENTIONAL SCATTER PLOT
The Japanese national quality award.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Mistake-proofing.
Prevention - appraisal - internal failure - external failure.

10. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Lean (or JIT).
A tool that shows the physical flows through a space.
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
99.73%

11. What is the center line of a p-chart?
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
p-bar - the long-run percent defective.
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.

12. What is Jidoka?
No -- only if the process is also capable.
Controlling quality at the source.
Mean time to failure.
Mean time to replacement.

13. What is a Gage R&R?
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).
The ratio of outputs to inputs; 1-scrap.
Speed - courtesy - competence - and ease of repair.
Because the mean and standard deviation are independent of each other.

14. For what is a p-chart used?
To monitor a process when measurement by attribute is used.
Controlling quality at the source.
To obtain a certain desirable outcome from the process
Linearity - normality - homoscedasticity - independence.

15. What is poka yoke?
Mistake-proofing.
Fishbone - cause-and-effect diagram.
p-bar - the long-run percent defective.
Central Limit Theorem

16. What is an affinity diagram?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
A brainstorming tool that shows the connections between ideas.
A tool that shows where there is waste in a process.
Controlling quality at the source.

17. What is the 5S model?
Method developed by Ishikawa to graphically display the causes of any given problem
Not necessarily.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
X-bar-bar

18. With Six Sigma capability - how many defects per million opportunities would you see?
The US national quality award.
3.4 (assuming 1.5 sigma shift in the mean)
No -- if it is not the same - it can only be worse!
QFD

19. Process occurance ranking
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
A brainstorming tool that shows the connections between ideas.
The US national quality award.
0.9^3 or 72.9%

20. If a three-stage process has 90% yields at each stage - what is the overall yield?
10 for Hazardous without warning 1 for none
0.9^3 or 72.9%
The secondary characteristics of a product; "bells and whistles."
Producer risk.

21. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Conformance to specifications.
The manager in charge of a process being improved in a Six Sigma project.
Hold all input variables constant except one. Observe the response as you vary the single input.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

22. Test for constant variance
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 tool that shows where there is waste in a process.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

23. What is a Pareto chart?
The gap between what customers expect and the service they receive.
A descending order-sorted bar chart with a cumulative percentage line.
X-bar-bar
Outside.

24. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Producer risk.
Look for the assignable cause of non-random variation.
5%

25. Uses of regression
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
F_alpha - df(tr) - df (error)

26. For what is an x-bar chart used?
To monitor a process when measurement by variables is used.
Concluding there has not been an effect/change when there has.
Lower skill requirements - faster - less chance for error.
To obtain a certain desirable outcome from the process

27. What are the four categories of costs in Juran's framework?
Prevention - appraisal - internal failure - external failure.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Define - measure - analyze - improve - control.
The gap between what management thinks customers want and the process specifications.

28. List two components of internal failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Initiated before or at design concept finalization
What the value of the dependent variable is when the independent variable is zero.
The House of Quality.

29. FMEA
Fewer good units to sell - increased variable cost/unit.
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
Is what induces the failure
Producer risk.

30. Define durability.
Consumer risk.
Mean time to replacement.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
3.4 (assuming 1.5 sigma shift in the mean)

31. Who is a process owner?
Shows the temporal flow of activities in a project network.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Initiated before or at design concept finalization
The manager in charge of a process being improved in a Six Sigma project.

32. Define performance quality.
Scrap - rework - retest - downtime - yield losses - disposition costs.
The primary operating characteristics of a product.
Assigns scores to weighted criteria for each project under consideration.
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

33. Cause and Effect Diagrams
Used to create frequency distribution tally sheets
The US national quality award.
Method developed by Ishikawa to graphically display the causes of any given problem
Mistake-proofing.

34. If you can only collect categorical data - what type of SPC charting can you do?
10 for Hazardous without warning 1 for none
Prevention - appraisal - internal failure - external failure.
p-bar - the long-run percent defective.
Attribute.

35. Regression
Represents the behavior of a process
=sqrt((p*(1-p)/n)
Variable.
To manage the Six Sigma project.

36. In a regression - what does the coefficient of the intercept tell you
Mistake-proofing.
68%
What the value of the dependent variable is when the independent variable is zero.
Lower skill requirements - faster - less chance for error.

37. Uses of regression - Control
To obtain a certain desirable outcome from the process
Fishbone - cause-and-effect diagram.
Variable.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

38. Detection Criteria Ranking
= yij - y(bar)i --> value minus sum of that treatment (of row)
=sqrt(Σ(x-x-bar)^2)/(n-1))
10 if Almost impossible to detect
0.9^3 or 72.9%

39. What is the Deming Prize?
Lean (or JIT).
The Japanese national quality award.
Define - measure - analyze - design - verify.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

40. In the Service Quality Gap Model - what is Gap 1?
Variable.
Look for the assignable cause of non-random variation.
Assigns scores to weighted criteria for each project under consideration.
The gap between what management thinks customers want and what customers really want.

41. What is the role of a master black belt?
To mentor/coach (and sometimes train) black belts.
The gap between specifications and how service is performed.
Producer risk.
Workers - machines - materials.

42. FMEA
It looks to minimize the probability of a failure - or to minimize its effects
=sqrt(Σ(x-x-bar)^2)/(n-1))
The target number of standard deviations from the mean for specifications.
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).

43. Define conformance quality.
Walter A. Shewhart
The degree to which a product meets pre-established standards.
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
QFD

44. What is a network diagram?
A diagram that shows the relationships between activities in a project network.
Financial - customer - internal process - innovation and learning.
A brainstorming tool that shows the connections between ideas.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

45. ANOVA

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46. Name the structure associated with Quality Function Deployment.
The House of Quality.
A scatterplot.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Is the consequence of the failure.

47. Defect check sheets
Different types of defects are listed (used for Pareto chart)
Prevention - appraisal - internal failure - external failure.
Attribute
To mentor/coach (and sometimes train) black belts.

48. What is Type II Error?
No -- only if the process is also capable.
Concluding there has not been an effect/change when there has.
Organize ideas into meaningful categories by recognizing their underlying similarity
The cycle time required to meet demand.

49. In the Service Quality Gap Model - what is Gap 2?
Look for the assignable cause of non-random variation.
The gap between what management thinks customers want and the process specifications.
Mistake-proofing.
What the value of the dependent variable is when the independent variable is zero.

50. Daniel Test
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
Rapid improvement process.
False - because each machine will have different natural tolerances.
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: