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Six Sigma

Subjects : certifications, six-sigma, business-skills

Instructions:

Answer 50 questions in 15 minutes.
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Match each statement with the correct term.
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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. Your production process meets customer specifications. Is your process in control?
Waste.
Pleasing to the senses.
Not necessarily.
Consumer risk.

2. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
The gap between what customers expect and the service they receive.
Conformance to specifications.
Fitness for use.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

3. What percentage of a normal distribution lies above the mean?
Initiated before or at design concept finalization
50%
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
=sqrt(Σ(x-x-bar)^2)/(n-1))

4. Test for Independence
To be a member of a Six Sigma project team.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
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
Organize ideas into meaningful categories by recognizing their underlying similarity

5. Definition of Interaction
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
50%
Lean (or JIT).

6. What is the center line of an X-bar 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
95%
X-bar-bar
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

7. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Walter A. Shewhart
They move closer to the center line.
Brand image.
Prevention and appraisal costs are balanced against internal and external failure.

8. What size should samples be for attribute SPC?
The degree to which a product meets pre-established standards.
QFD
Assigns scores to weighted criteria for each project under consideration.
Large enough to find two of the attribute - on average.

9. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
A time series plot.
99.73%
The gap between what management thinks customers want and what customers really want.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

10. Defect location check sheets
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Concluding there has been an effect/change when there has not.
Actual drawings - layouts - maps - etc which show where a defect occurs
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

11. In the Service Quality Gap Model - what is Gap 4?
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.
Large enough to find two of the attribute - on average.
Outside.
The gap between what is promised and what is delivered.

12. Manual Test for Nomality
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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
The degree to which a product meets pre-established standards.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

13. In the Service Quality Gap Model - what is Gap 1?
The gap between what management thinks customers want and what customers really want.
Prevention and appraisal costs are balanced against internal and external failure.
Outside.
p-bar - the long-run percent defective.

14. Which quality guru developed the concept of loss to society?
It's good -- but it's still out of control!
Taguchi
Fitness for use.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

15. List two components of prevention cost.
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.
Prevention and appraisal costs are balanced against internal and external failure.
Prevention - appraisal - internal failure - external failure.

16. Affinity Diagrams
A tool that shows the physical flows through a space.
Supplier - input - process - output - customer.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Organize ideas into meaningful categories by recognizing their underlying similarity

17. List two appraisal costs.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
A tool that shows the physical flows through a space.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

18. What is DPMO?
Defects Per Million Opportunities
A tool that shows the physical flows through a space.
Different types of defects are listed (used for Pareto chart)
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

19. What does the abbreviation LCL stand for?
Lower control limit.
A time series plot.
Producer risk.
Is what induces the failure

20. Statistical Hypothesis
The gap between what customers expect and the service they receive.
To mentor/coach (and sometimes train) black belts.
An assertion or conjecture concerning one or more populations
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

21. Who developed the fishbone diagram?
Waste.
The US national quality award.
99.73%
Kaoru Ishikawa.

22. Affinity Diagrams
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Define - measure - analyze - design - verify.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Supplier - input - process - output - customer.

23. FMEA
Stratify a particular defect type according to logical criteria
False - because each machine will have different natural tolerances.
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

24. What is the role of a black belt?
False - because each machine will have different natural tolerances.
To manage the Six Sigma project.
Assigns scores to weighted criteria for each project under consideration.
A tool that shows performance along key dimensions all at once.

25. Explain the difference between technical and functional service quality.
Mean time to failure.
Deming.
Hold all input variables constant except one. Observe the response as you vary the single input.
Technical quality is the "what" of the service; functional quality is the "how."

26. What type of risk is associated with Type II Error?
Consumer risk.
= yij - y(bar)i --> value minus sum of that treatment (of row)
100%
10 for Hazardous without warning 1 for none

27. What is a network diagram?
The gap between what is promised and what is delivered.
Studying firms with the best performance in a particular area.
A diagram that shows the relationships between activities in a project network.
Taguchi

28. What is a CAVE man?
Someone who is consistently against virtually everything.
Mistake-proofing.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
To be a member of a Six Sigma project team.

29. What does the abbreviation UCL stand for?
The ratio of outputs to inputs; 1-scrap.
It's good -- but it's still out of control!
Upper control limit.
The gap between specifications and how service is performed.

30. What is a run chart?
50%
Attribute
Lower skill requirements - faster - less chance for error.
A time series plot.

31. To what does the Six in Six Sigma relate?
An assertion or conjecture concerning one or more populations
Supplier - input - process - output - customer.
They move closer to the center line.
The target number of standard deviations from the mean for specifications.

32. List two components of external failure.
Walter A. Shewhart
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Mistake-proofing.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

33. What quality tool formally incorporates the voice of the customer?
Different types of defects are listed (used for Pareto chart)
Method developed by Ishikawa to graphically display the causes of any given problem
QFD
3.4 (assuming 1.5 sigma shift in the mean)

34. What is Value Stream Mapping?
99.73%
The ability of a process to consistently meet customer specifications.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
A tool that shows where there is waste in a process.

35. What is the center line of a p-chart?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
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
Attribute
p-bar - the long-run percent defective.

36. Risk Priority Number RPN
To mentor/coach (and sometimes train) black belts.
Upper control limit.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

37. Process check sheets
The gap between what customers expect and the service they receive.
Can't tell without a Range chart.
Failure Modes and Effects Analysis
Used to create frequency distribution tally sheets

38. What happens to control limits on an SPC chart when sample size is increased?
Sort - Set in Order - Shine - Standardize - Sustain
They move closer to the center line.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
A tool that shows where there is waste in a process.

39. Effect ranking (Severity of the Defect)
10 for Hazardous without warning 1 for none
A descending order-sorted bar chart with a cumulative percentage line.
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
68%

40. If you can only collect categorical data - what type of SPC charting can you do?
Attribute.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
10 for Hazardous without warning 1 for none

41. Defect check sheets
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:
Different types of defects are listed (used for Pareto chart)
Reliability - Assurance - Responsiveness - Tangibles - Empathy
99.73%

42. Daniel Test
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Brand image.
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:
68%

43. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Mean time to replacement.
Attribute
The degree to which a product meets pre-established standards.
Attribute.

44. Uses of regression
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
A tool that shows performance along key dimensions all at once.
Is what induces the failure
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

45. What is a Gantt chart?
50%
Shows the temporal flow of activities in a project network.
What the value of the dependent variable is when the independent variable is zero.
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:

46. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Controlling quality at the source.
Variable.
QFD

47. What is an affinity diagram?
A brainstorming tool that shows the connections between ideas.
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.
To monitor a process when measurement by variables is used.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

48. Non-random patterns (Run Charts)
Shifts - Trends - Repeating patterns - Correlation with known events
X-bar-bar
Studying firms with the best performance in a particular area.
The degree to which a product meets pre-established standards.

49. Uses of regression - Control
To obtain a certain desirable outcome from the process
Upper control limit.
The target number of standard deviations from the mean for specifications.
50%

50. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
0.9^3 or 72.9%
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
100%
Assigns scores to weighted criteria for each project under consideration.

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