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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. Define takt time.
Assigns scores to weighted criteria for each project under consideration.
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:
Failure Modes and Effects Analysis
The cycle time required to meet demand.

2. What do you do when a process is out of control?
Shifts - Trends - Repeating patterns - Correlation with known events
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).
To mentor/coach (and sometimes train) black belts.
Look for the assignable cause of non-random variation.

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

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4. FMEA
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
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
= 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
Supplier - input - process - output - customer.

5. Does it ever make sense to accept a job when a process is incapable?
To obtain a certain desirable outcome from the process
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Lower control limit.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

6. Defect location check sheets
Blame.
Actual drawings - layouts - maps - etc which show where a defect occurs
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).
Through producer/consumer negotiation.

7. What is Type 1 Error?
Look for the assignable cause of non-random variation.
Deming.
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
Concluding there has been an effect/change when there has not.

8. What is CTQ?
The gap between what management thinks customers want and the process specifications.
Observed variation in response is caused by the input
A tool that shows where there is waste in a process.
Critical to quality.

9. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Shifts - Trends - Repeating patterns - Correlation with known events
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Taguchi
Attribute

10. Design of Experiments (DOE) approach
Defects Per Million Opportunities
To mentor/coach (and sometimes train) black belts.
To obtain a certain desirable outcome from the process
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

11. Cause and Effect Diagrams
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
Method developed by Ishikawa to graphically display the causes of any given problem
A diagram that shows the relationships between activities in a project network.
The target number of standard deviations from the mean for specifications.

12. Histogram by Hand
To monitor a process when measurement by attribute is used.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Speed - courtesy - competence - and ease of repair.
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

13. Affinity Diagrams
Organize ideas into meaningful categories by recognizing their underlying similarity
Failure Modes and Effects Analysis
0.9^3 or 72.9%
Attribute.

14. Taguchi's experimental designs are of this type.
Fractional factorial designs (orthogonal arrays)
Pleasing to the senses.
10 for Hazardous without warning 1 for none
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

15. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
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.

16. To what does the Six in Six Sigma relate?
The target number of standard deviations from the mean for specifications.
Speed - courtesy - competence - and ease of repair.
An assertion or conjecture concerning one or more populations
p-bar - the long-run percent defective.

17. Detection Criteria Ranking
100%
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
10 if Almost impossible to detect
Variable.

18. If a Cp shows that a process is not capable - should you calculate Cpk?
No -- if it is not the same - it can only be worse!
What the value of the dependent variable is when the independent variable is zero.
The ability of a process to consistently meet customer specifications.
A random variable that summarizes the information from the sample(s).

19. 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 secondary characteristics of a product; "bells and whistles."
False - because each machine will have different natural tolerances.
10 for Hazardous without warning 1 for none

20. What is the difference between Lean and Six Sigma?
False - because each machine will have different natural tolerances.
Lean is waste reduction - Six Sigma is variation reduction.
=sqrt(Σ(x-x-bar)^2)/(n-1))
To manage the Six Sigma project.

21. If a three-stage process has 90% yields at each stage - what is the overall yield?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
5%
0.9^3 or 72.9%
The number of standard deviations some value is from the mean.

22. What does the abbreviation LCL stand for?
Supplier - input - process - output - customer.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Before production starts
Lower control limit.

23. What type of risk is associated with Type II Error?
Prevention - appraisal - internal failure - external failure.
Kaoru Ishikawa.
Consumer risk.
False - because each machine will have different natural tolerances.

24. Based on what principal can we use the normal distribution assumptions for SPC?
Workers - machines - materials.
Central Limit Theorem
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
=sqrt((p*(1-p)/n)

25. What is the formula for standard deviation?
=sqrt(Σ(x-x-bar)^2)/(n-1))
Method developed by Ishikawa to graphically display the causes of any given problem
Is the way in which the failure is manifested.
Controlling quality at the source.

26. What is a Gantt chart?
Lower skill requirements - faster - less chance for error.
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:
99.73%
Shows the temporal flow of activities in a project network.

27. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
Fewer good units to sell - increased variable cost/unit.
Causes that lead to a particular effect.
To obtain a certain desirable outcome from the process

28. What are the Five Dimensions of Service Quality?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Attribute
Pleasing to the senses.
Critical to quality.

29. What percentage of a normal distribution lies above the mean?
Variable.
50%
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
Critical to quality.

30. What are two other names for an Ishikawa diagram?
Fishbone - cause-and-effect diagram.
The target number of standard deviations from the mean for specifications.
QFD
Different types of defects are listed (used for Pareto chart)

31. Define benchmarking.
Inventory = throughput x flow time.
Studying firms with the best performance in a particular area.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A time series plot.

32. For what is a p-chart used?
The number of standard deviations some value is from the mean.
68%
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 monitor a process when measurement by attribute is used.

33. Risk Priority Number RPN
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
To be a member of a Six Sigma project team.
Large enough to find two of the attribute - on average.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

34. Process check sheets
To mentor/coach (and sometimes train) black belts.
Observed variation in response is caused by the input
Used to create frequency distribution tally sheets
Upper control limit.

35. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
To mentor/coach (and sometimes train) black belts.
Sort - Set in Order - Shine - Standardize - Sustain
No -- the variation also has to be random and "expected."
Initiated before or at design concept finalization

36. Which type of SPC measurement is more precise - variable or attribute?
Variable.
The gap between what management thinks customers want and what customers really want.
Not necessarily.
Prevention - appraisal - internal failure - external failure.

37. What is Little's Law?
Inventory = throughput x flow time.
Deming.
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

38. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
F_alpha - df(tr) - df (error)
68%

39. Define yield.
X-bar-bar
The cycle time required to meet demand.
Mean time to failure.
The ratio of outputs to inputs; 1-scrap.

40. Who is a process owner?
Fractional factorial designs (orthogonal arrays)
They move closer to the center line.
False - because each machine will have different natural tolerances.
The manager in charge of a process being improved in a Six Sigma project.

41. What are the three main categories of assignable cause?
A time series plot.
Fewer good units to sell - increased variable cost/unit.
Mistake-proofing.
Workers - machines - materials.

42. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Concluding there has not been an effect/change when there has.
Sampling for SPC is done real time.
No -- only if the process is also capable.
Fitness for use.

43. What size should samples be for attribute SPC?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
A scatterplot.
Large enough to find two of the attribute - on average.
Workers - machines - materials.

44. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
Concluding there has not been an effect/change when there has.
Deming.
Fractional factorial designs (orthogonal arrays)

45. Define product reliability.
Workers - machines - materials.
The ability of a process to consistently meet customer specifications.
Mean time to failure.
A descending order-sorted bar chart with a cumulative percentage line.

46. The Test Statistic (TS)
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
A random variable that summarizes the information from the sample(s).
They move closer to the center line.
It's good -- but it's still out of control!

47. Stratified defect check sheets
Stratify a particular defect type according to logical criteria
68%
Mistake-proofing.
= yij - y(bar)i --> value minus sum of that treatment (of row)

48. Affinity Diagrams
Speed - courtesy - competence - and ease of repair.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
To obtain a certain desirable outcome from the process
Outside.

49. 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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50. What happens to control limits on an SPC chart when sample size is increased?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Concluding there has not been an effect/change when there has.
They move closer to the center line.
Kaoru Ishikawa.