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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. 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.
Organize ideas into meaningful categories by recognizing their underlying similarity
The number of standard deviations some value is from the mean.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

2. What is a Gantt chart?
p-bar - the long-run percent defective.
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
Shows the temporal flow of activities in a project network.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

3. Creating a Run Chart
The ratio of outputs to inputs; 1-scrap.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Fewer good units to sell - increased variable cost/unit.
What the value of the dependent variable is when the independent variable is zero.

4. What is a CAVE man?
No -- only if the process is also capable.
Workers - machines - materials.
Someone who is consistently against virtually everything.
The gap between what is promised and what is delivered.

5. What are the four perspectives of the Balanced Scorecard?
Financial - customer - internal process - innovation and learning.
Kaoru Ishikawa.
Not necessarily.
Scrap - rework - retest - downtime - yield losses - disposition costs.

6. List Garvin's eight dimensions of product quality.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Inventory = throughput x flow time.
= 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

7. Complete this quality phrase: 'Fix the process - not the _____.'
Represents the behavior of a process
Is what induces the failure
To mentor/coach (and sometimes train) black belts.
Blame.

8. If a three-stage process has 90% yields at each stage - what is the overall yield?
0.9^3 or 72.9%
X-bar-bar
Kaoru Ishikawa.
Prevention and appraisal costs are balanced against internal and external failure.

9. Risk Priority Number RPN
Walter A. Shewhart
Taguchi
= 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.

10. Detection Criteria Ranking
10 if Almost impossible to detect
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
Fractional factorial designs (orthogonal arrays)
Prevention - appraisal - internal failure - external failure.

11. In the Service Quality Gap Model - what is Gap 2?
The gap between what management thinks customers want and the process specifications.
3.4 (assuming 1.5 sigma shift in the mean)
No -- the variation also has to be random and "expected."
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

12. Pareto Analysis
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The cycle time required to meet demand.
Before production starts
Critical to quality.

13. What are the Five Dimensions of Service Quality?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Method developed by Ishikawa to graphically display the causes of any given problem
Fewer good units to sell - increased variable cost/unit.
The gap between what management thinks customers want and the process specifications.

14. Test for Independence
Supplier - input - process - output - customer.
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
It's good -- but it's still out of control!
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

15. What does DMAIC stand for?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Define - measure - analyze - improve - control.
Organize ideas into meaningful categories by recognizing their underlying similarity
To monitor a process when measurement by attribute is used.

16. For what is a p-chart used?
To monitor a process when measurement by attribute is used.
Sampling for SPC is done real time.
=sqrt((p*(1-p)/n)
Used to create frequency distribution tally sheets

17. Definition of Interaction
Linearity - normality - homoscedasticity - independence.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Stratify a particular defect type according to logical criteria
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

18. Uses of regression
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The gap between what management thinks customers want and what customers really want.
Before production starts
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

19. What is FMEA?
Look for the assignable cause of non-random variation.
Shifts - Trends - Repeating patterns - Correlation with known events
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Failure Modes and Effects Analysis

20. FMEA
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
Outside.
Sampling for SPC is done real time.
Workers - machines - materials.

21. What is the 5S model?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Represents the behavior of a process
Before production starts
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

22. What is the center line of a p-chart?
Kaoru Ishikawa.
p-bar - the long-run percent defective.
A descending order-sorted bar chart with a cumulative percentage line.
What the value of the dependent variable is when the independent variable is zero.

23. What is a Pareto chart?
A descending order-sorted bar chart with a cumulative percentage line.
Not necessarily.
Stratify a particular defect type according to logical criteria
Variable.

24. What is poka yoke?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Mistake-proofing.
Organize ideas into meaningful categories by recognizing their underlying similarity

25. How does Juran define quality?
The Japanese national quality award.
Stratify a particular defect type according to logical criteria
Fitness for use.
Linearity - normality - homoscedasticity - independence.

26. FMEA
It looks to minimize the probability of a failure - or to minimize its effects
Fishbone - cause-and-effect diagram.
Waste.
Different types of defects are listed (used for Pareto chart)

27. What is the difference between Lean and Six Sigma?
They move closer to the center line.
Mean time to replacement.
Lean is waste reduction - Six Sigma is variation reduction.
Brand image.

28. What is DPMO?
Inventory = throughput x flow time.
The ratio of outputs to inputs; 1-scrap.
=sqrt((p*(1-p)/n)
Defects Per Million Opportunities

29. What is an affinity diagram?
The manager in charge of a process being improved in a Six Sigma project.
Variable.
Upper control limit.
A brainstorming tool that shows the connections between ideas.

30. 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).
=sqrt((p*(1-p)/n)
Method developed by Ishikawa to graphically display the causes of any given problem
The secondary characteristics of a product; "bells and whistles."

31. Define benchmarking.
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:
Rapid improvement process.
Studying firms with the best performance in a particular area.
Workers - machines - materials.

32. Who is a process owner?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
50%
The manager in charge of a process being improved in a Six Sigma project.
0.9^3 or 72.9%

33. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Method developed by Ishikawa to graphically display the causes of any given problem
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Pleasing to the senses.
Variable.

34. Taguchi's experimental designs are of this type.
Deming.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Fractional factorial designs (orthogonal arrays)
The US national quality award.

35. In a regression - what does R-square tell you?
Causes that lead to a particular effect.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The gap between what is promised and what is delivered.
Rapid improvement process.

36. Defect location check sheets
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
To monitor a process when measurement by attribute is used.
Actual drawings - layouts - maps - etc which show where a defect occurs
The House of Quality.

37. In a regression - what does the p value of F tell you?
The secondary characteristics of a product; "bells and whistles."
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).
Blame.
To monitor a process when measurement by attribute is used.

38. What is CTQ?
Taguchi
= 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
Critical to quality.
100%

39. Define serviceability.
To monitor a process when measurement by attribute is used.
Speed - courtesy - competence - and ease of repair.
68%
Defects Per Million Opportunities

40. In Juran's Cost of Quality model - which categories of costs balance which other categories?
The House of Quality.
Inventory = throughput x flow time.
A tool that shows performance along key dimensions all at once.
Prevention and appraisal costs are balanced against internal and external failure.

41. List two components of prevention cost.
Rapid improvement process.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
The manager in charge of a process being improved in a Six Sigma project.
Concluding there has been an effect/change when there has not.

42. What are the three main categories of assignable cause?
Initiated before or at design concept finalization
Workers - machines - materials.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Walter A. Shewhart

43. What is the formula for standard deviation?
Controlling quality at the source.
False - because each machine will have different natural tolerances.
The primary operating characteristics of a product.
=sqrt(Σ(x-x-bar)^2)/(n-1))

44. Define yield.
What the value of the dependent variable is when the independent variable is zero.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
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
The ratio of outputs to inputs; 1-scrap.

45. Design of Experiments (DOE) approach
Scrap - rework - retest - downtime - yield losses - disposition costs.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Rapid improvement process.
A tool that shows performance along key dimensions all at once.

46. What is a histogram?
Assigns scores to weighted criteria for each project under consideration.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
To monitor a process when measurement by variables is used.
The cycle time required to meet demand.

47. What is muda
Pleasing to the senses.
Waste.
100%
No -- if it is not the same - it can only be worse!

48. Histogram by Hand
Variable.
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
Supplier - input - process - output - customer.
10 for Hazardous without warning 1 for none

49. Manual Test for Nomality
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
A diagram that shows the relationships between activities in a project network.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Is the way in which the failure is manifested.

50. Residual
Fewer good units to sell - increased variable cost/unit.
Fractional factorial designs (orthogonal arrays)
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
68%