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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. Residual(eij)
= yij - y(bar)i --> value minus sum of that treatment (of row)
Kaoru Ishikawa.
=sqrt(Σ(x-x-bar)^2)/(n-1))
The secondary characteristics of a product; "bells and whistles."

2. What is process capability?
5%
Blame.
Walter A. Shewhart
The ability of a process to consistently meet customer specifications.

3. What are two other names for an Ishikawa diagram?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
To be a member of a Six Sigma project team.
To mentor/coach (and sometimes train) black belts.
Fishbone - cause-and-effect diagram.

4. Affinity Diagrams
To obtain a certain desirable outcome from the process
100%
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Prevention - appraisal - internal failure - external failure.

5. If a three-stage process has 90% yields at each stage - what is the overall yield?
0.9^3 or 72.9%
Lower skill requirements - faster - less chance for error.
They move closer to the center line.
The manager in charge of a process being improved in a Six Sigma project.

6. What is poka yoke?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Reliability - Assurance - Responsiveness - Tangibles - Empathy
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Mistake-proofing.

7. What is a network diagram?
A diagram that shows the relationships between activities in a project network.
Supplier - input - process - output - customer.
Large enough to find two of the attribute - on average.
Initiated before or at design concept finalization

8. List two appraisal costs.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Mistake-proofing.
To obtain a certain desirable outcome from the process

9. Histogram by Hand
95%
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
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Fitness for use.

10. One factor at a time (OFAT)
= yij - y(bar)i --> value minus sum of that treatment (of row)
Observed variation in response is caused by the input
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Sampling for SPC is done real time.

11. List Garvin's eight dimensions of product quality.
Prevention - appraisal - internal failure - external failure.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Not necessarily.
Variable.

12. What do you do when a process is out of control?
The primary operating characteristics of a product.
Look for the assignable cause of non-random variation.
Define - measure - analyze - design - verify.
Variable.

13. Which type of SPC measurement is more precise - variable or attribute?
Variable.
Observed variation in response is caused by the input
0.9^3 or 72.9%
Represents the behavior of a process

14. Failure cause
Scrap - rework - retest - downtime - yield losses - disposition costs.
Is what induces the failure
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
A tool that shows where there is waste in a process.

15. Test for Independence
5%
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
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Can't tell without a Range chart.

16. DFMEA
The cycle time required to meet demand.
Initiated before or at design concept finalization
Studying firms with the best performance in a particular area.
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

17. What is the Deming Prize?
A diagram that shows the relationships between activities in a project network.
Shifts - Trends - Repeating patterns - Correlation with known events
Prevention - appraisal - internal failure - external failure.
The Japanese national quality award.

18. What is the formula for standard deviation?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
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
=sqrt(Σ(x-x-bar)^2)/(n-1))
3.4 (assuming 1.5 sigma shift in the mean)

19. What does DMAIC stand for?
Initiated before or at design concept finalization
Concluding there has not been an effect/change when there has.
Define - measure - analyze - improve - control.
Lean is waste reduction - Six Sigma is variation reduction.

20. In the Service Quality Gap Model - what is Gap 5?
The gap between what customers expect and the service they receive.
Defects Per Million Opportunities
Define - measure - analyze - improve - control.
Consumer risk.

21. How are LQL and AQL determined in an acceptance sampling plan?
Assigns scores to weighted criteria for each project under consideration.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Through producer/consumer negotiation.
Different types of defects are listed (used for Pareto chart)

22. Non-random patterns (Run Charts)
Shifts - Trends - Repeating patterns - Correlation with known events
Kaoru Ishikawa.
Prevention - appraisal - internal failure - external failure.
Through producer/consumer negotiation.

23. Presence of interaction effect
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

24. What does the abbreviation LCL stand for?
Lower control limit.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
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).
Stratify a particular defect type according to logical criteria

25. What is Little's Law?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Rapid improvement process.
Actual drawings - layouts - maps - etc which show where a defect occurs
Inventory = throughput x flow time.

26. TWO-DIMENTIONAL SCATTER PLOT
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Mean time to replacement.

27. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
The degree to which a product meets pre-established standards.
5%
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Look for the assignable cause of non-random variation.

28. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
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:
False - because each machine will have different natural tolerances.
Variable.
The gap between what management thinks customers want and the process specifications.

29. What is the Baldrige Award?
To obtain a certain desirable outcome from the process
The gap between specifications and how service is performed.
The US national quality award.
50%

30. List two components of external failure.
The Japanese national quality award.
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
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
A brainstorming tool that shows the connections between ideas.

31. How does Juran define quality?
Fitness for use.
Represents the behavior of a process
Mean time to replacement.
95%

32. In a regression - what does the p value of F tell you?
The cycle time required to meet demand.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
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).
To monitor a process when measurement by attribute is used.

33. Define conformance quality.
Represents the behavior of a process
Organize ideas into meaningful categories by recognizing their underlying similarity
The degree to which a product meets pre-established standards.
68%

34. Pareto Analysis
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Consumer risk.
Mistake-proofing.
Before production starts

35. FMEA
Fishbone - cause-and-effect diagram.
Define - measure - analyze - improve - control.
It looks to minimize the probability of a failure - or to minimize its effects
=sqrt(Σ(x-x-bar)^2)/(n-1))

36. Regression
The primary operating characteristics of a product.
F_alpha - df(tr) - df (error)
Represents the behavior of a process
The gap between what is promised and what is delivered.

37. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
Define - measure - analyze - improve - control.
Initiated before or at design concept finalization
The number of standard deviations some value is from the mean.

38. Daniel Test
Studying firms with the best performance in a particular area.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
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:
Reliability - Assurance - Responsiveness - Tangibles - Empathy

39. ANOVA

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40. What does SIPOC stand for?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Supplier - input - process - output - customer.
Shifts - Trends - Repeating patterns - Correlation with known events
Deming.

41. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Concluding there has been an effect/change when there has not.
Attribute
No -- if it is not the same - it can only be worse!
1.Interactions can be detected and measured 2.Each value does the work of several values 3.Experimental error is quantified and used to determine the confidence the experimenter has in the conclusions

42. What is the 5S model?
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
A tool that shows the physical flows through a space.

43. What is the difference between the way sampling is done for SPC and for acceptance sampling?
To monitor a process when measurement by variables is used.
Taguchi
Sampling for SPC is done real time.
Walter A. Shewhart

44. What are the Five Dimensions of Service Quality?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Look for the assignable cause of non-random variation.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Mean time to replacement.

45. What is DPMO?
Defects Per Million Opportunities
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:
Failure Modes and Effects Analysis

46. Failure effect
A descending order-sorted bar chart with a cumulative percentage line.
The House of Quality.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Is the consequence of the failure.

47. Risk Priority Number RPN
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Supplier - input - process - output - customer.
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

48. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Variable.
Waste.
Prevention and appraisal costs are balanced against internal and external failure.
99.73%

49. There are two milling machines in the shop. Data has been collected on one to compute control limits for both. This is acceptable SPC practice - true or false and why?
Variable.
Represents the behavior of a process
False - because each machine will have different natural tolerances.
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

50. Uses of regression - Control
A random variable that summarizes the information from the sample(s).
To obtain a certain desirable outcome from the process
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Taguchi