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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. Cause and Effect Diagrams
They move closer to the center line.
Sort - Set in Order - Shine - Standardize - Sustain
Method developed by Ishikawa to graphically display the causes of any given problem
The gap between what customers expect and the service they receive.

2. If you have calculated a Cpk - should you also calculate a Cp?
Kaoru Ishikawa.
Prevention and appraisal costs are balanced against internal and external failure.
The ability of a process to consistently meet customer specifications.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

3. One factor at a time (OFAT)
Organize ideas into meaningful categories by recognizing their underlying similarity
No -- if it is not the same - it can only be worse!
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Hold all input variables constant except one. Observe the response as you vary the single input.

4. Manual Test for Nomality
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
The ability of a process to consistently meet customer specifications.

5. What is Value Stream Mapping?
Variable.
The gap between specifications and how service is performed.
A tool that shows where there is waste in a process.
Waste.

6. What is a run chart?
The number of standard deviations some value is from the mean.
A time series plot.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
A tool that shows the physical flows through a space.

7. Failure cause
10 if Almost impossible to detect
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
Prevention and appraisal costs are balanced against internal and external failure.
Is what induces the failure

8. In a regression - what does the p value of F tell you?
Prevention - appraisal - internal failure - external failure.
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).
X-bar-bar
Deming.

9. What is an affinity diagram?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Lower control limit.
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

10. What is a Gage R&R?
A random variable that summarizes the information from the sample(s).
Defects Per Million Opportunities
A descending order-sorted bar chart with a cumulative percentage line.
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).

11. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
p-bar - the long-run percent defective.
95%
10 if Almost impossible to detect
The gap between what management thinks customers want and what customers really want.

12. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Inventory = throughput x flow time.
A descending order-sorted bar chart with a cumulative percentage line.
68%
Stratify a particular defect type according to logical criteria

13. What is written on the "spines" of a fishbone diagram?
Causes that lead to a particular effect.
Financial - customer - internal process - innovation and learning.
Studying firms with the best performance in a particular area.
Lean is waste reduction - Six Sigma is variation reduction.

14. Stratified defect check sheets
Producer risk.
To mentor/coach (and sometimes train) black belts.
Stratify a particular defect type according to logical criteria
Large enough to find two of the attribute - on average.

15. Define conformance quality.
The degree to which a product meets pre-established standards.
The manager in charge of a process being improved in a Six Sigma project.
The secondary characteristics of a product; "bells and whistles."
False - because each machine will have different natural tolerances.

16. In the Service Quality Gap Model - what is Gap 4?
Concluding there has been an effect/change when there has not.
Taguchi
A descending order-sorted bar chart with a cumulative percentage line.
The gap between what is promised and what is delivered.

17. What is DPMO?
Inventory = throughput x flow time.
Defects Per Million Opportunities
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Kaoru Ishikawa.

18. What is FMEA?
Failure Modes and Effects Analysis
The manager in charge of a process being improved in a Six Sigma project.
The ratio of outputs to inputs; 1-scrap.
Prevention and appraisal costs are balanced against internal and external failure.

19. With Six Sigma capability - how many defects per million opportunities would you see?
Sampling for SPC is done real time.
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:
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
3.4 (assuming 1.5 sigma shift in the mean)

20. In a Z table - what is Z?
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 number of standard deviations some value is from the mean.
Sort - Set in Order - Shine - Standardize - Sustain
Critical to quality.

21. Non-random patterns (Run Charts)
Shifts - Trends - Repeating patterns - Correlation with known events
To obtain a certain desirable outcome from the process
Is the consequence of the failure.
The target number of standard deviations from the mean for specifications.

22. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
The US national quality award.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Variable.
Can't tell without a Range chart.

23. Does it ever make sense to accept a job when a process is incapable?
To mentor/coach (and sometimes train) black belts.
Controlling quality at the source.
To be a member of a Six Sigma project team.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

24. What are the Five Dimensions of Service Quality?
95%
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Represents the behavior of a process
0.9^3 or 72.9%

25. What is the formula for standard deviation?
A random variable that summarizes the information from the sample(s).
=sqrt(Σ(x-x-bar)^2)/(n-1))
Fewer good units to sell - increased variable cost/unit.
Linearity - normality - homoscedasticity - independence.

26. Based on what principal can we use the normal distribution assumptions for SPC?
Supplier - input - process - output - customer.
A scatterplot.
A tool that shows performance along key dimensions all at once.
Central Limit Theorem

27. When is Cpk used?
Fitness for use.
Through producer/consumer negotiation.
Mean time to replacement.
To do a capability study for a non-centered process.

28. Process occurance ranking
Because the mean and standard deviation are independent of each other.
Fitness for use.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Hold all input variables constant except one. Observe the response as you vary the single input.

29. Defect check sheets
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Different types of defects are listed (used for Pareto chart)
10 if Almost impossible to detect
Assigns scores to weighted criteria for each project under consideration.

30. What quality guru emphasizes management as a system?
Supplier - input - process - output - customer.
An assertion or conjecture concerning one or more populations
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Deming.

31. What is a histogram?
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
Define - measure - analyze - improve - control.
Mean time to replacement.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

32. Design of Experiments (DOE) approach
The secondary characteristics of a product; "bells and whistles."
Can't tell without a Range chart.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

33. What does DMAIC stand for?
The gap between what management thinks customers want and the process specifications.
Define - measure - analyze - improve - control.
Method developed by Ishikawa to graphically display the causes of any given problem
Can't tell without a Range chart.

34. What is a CAVE man?
Lower skill requirements - faster - less chance for error.
Someone who is consistently against virtually everything.
Workers - machines - materials.
Kaoru Ishikawa.

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

36. Test for Independence
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
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).
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
50%

37. Presence of interaction effect
A descending order-sorted bar chart with a cumulative percentage line.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Critical to quality.
99.73%

38. Process check sheets
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
No -- if it is not the same - it can only be worse!
Used to create frequency distribution tally sheets
Initiated before or at design concept finalization

39. Who developed the fishbone diagram?
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 US national quality award.
No -- only if the process is also capable.
Kaoru Ishikawa.

40. What is Little's Law?
Central Limit Theorem
Inventory = throughput x flow time.
Assigns scores to weighted criteria for each project under consideration.
A tool that shows the physical flows through a space.

41. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Prevention and appraisal costs are balanced against internal and external failure.
A descending order-sorted bar chart with a cumulative percentage line.

42. What does SIPOC stand for?
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.
Supplier - input - process - output - customer.
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:
Waste.

43. What is a dashboard?
The ratio of outputs to inputs; 1-scrap.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
The number of standard deviations some value is from the mean.
A tool that shows performance along key dimensions all at once.

44. DFMEA
68%
Initiated before or at design concept finalization
100%
To obtain a certain desirable outcome from the process

45. What are two other names for an Ishikawa diagram?
Outside.
Critical to quality.
Fishbone - cause-and-effect diagram.
An assertion or conjecture concerning one or more populations

46. Daniel Test
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
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:
No -- if it is not the same - it can only be worse!
Stratify a particular defect type according to logical criteria

47. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Not necessarily.
Prevention and appraisal costs are balanced against internal and external failure.
= 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

48. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
Concluding there has been an effect/change when there has not.
What the value of the dependent variable is when the independent variable is zero.
Kaoru Ishikawa.

49. What does the abbreviation LCL stand for?
Lower control limit.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
No -- only if the process is also capable.
Is the consequence of the failure.

50. ANOVA