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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. List two components of external failure.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Attribute.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

2. Daniel Test
A brainstorming tool that shows the connections between ideas.
10 for Hazardous without warning 1 for none
To monitor a process when measurement by variables is used.
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:

3. Effect ranking (Severity of the Defect)
10 for Hazardous without warning 1 for none
A random variable that summarizes the information from the sample(s).
A diagram that shows the relationships between activities in a project network.
Conformance to specifications.

4. DFMEA
A random variable that summarizes the information from the sample(s).
0.9^3 or 72.9%
Initiated before or at design concept finalization
Stratify a particular defect type according to logical criteria

5. What is a Gantt chart?
The Japanese national quality award.
The gap between what customers expect and the service they receive.
To monitor a process when measurement by variables is used.
Shows the temporal flow of activities in a project network.

6. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
99.73%
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
It's good -- but it's still out of control!
Variable.

7. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Is the way in which the failure is manifested.
Supplier - input - process - output - customer.
Variable.
Shifts - Trends - Repeating patterns - Correlation with known events

8. If you can only collect categorical data - what type of SPC charting can you do?
Attribute.
To manage the Six Sigma project.
Before production starts
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

9. Process check sheets
Financial - customer - internal process - innovation and learning.
To be a member of a Six Sigma project team.
Used to create frequency distribution tally sheets
The House of Quality.

10. Define serviceability.
Mean time to failure.
Speed - courtesy - competence - and ease of repair.
Through producer/consumer negotiation.
A random variable that summarizes the information from the sample(s).

11. What are the four categories of costs in Juran's framework?
To monitor a process when measurement by attribute is used.
An assertion or conjecture concerning one or more populations
Prevention - appraisal - internal failure - external failure.
A scatterplot.

12. Residual
Fitness for use.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The secondary characteristics of a product; "bells and whistles."
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. Uses of regression - Control
To obtain a certain desirable outcome from the process
Shifts - Trends - Repeating patterns - Correlation with known events
A time series plot.
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).

14. For what is a p-chart used?
Rapid improvement process.
5%
To monitor a process when measurement by attribute is used.
F_alpha - df(tr) - df (error)

15. How does Juran define quality?
Financial - customer - internal process - innovation and learning.
Fewer good units to sell - increased variable cost/unit.
Fitness for use.
Prevention and appraisal costs are balanced against internal and external failure.

16. What is a dashboard?
Through producer/consumer negotiation.
A tool that shows performance along key dimensions all at once.
Lean (or JIT).
Deming.

17. A process is operating "in control." Does this mean the customer's requirements are met?
Fractional factorial designs (orthogonal arrays)
No -- only if the process is also capable.
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:
Represents the behavior of a process

18. Who first studied randomness in industrial processes
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Walter A. Shewhart
Central Limit Theorem
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

19. What is written on the "spines" of a fishbone diagram?
Causes that lead to a particular effect.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Before production starts
Controlling quality at the source.

20. One factor at a time (OFAT)
Actual drawings - layouts - maps - etc which show where a defect occurs
Hold all input variables constant except one. Observe the response as you vary the single input.
Studying firms with the best performance in a particular area.
The manager in charge of a process being improved in a Six Sigma project.

21. F value
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Mean time to failure.
F_alpha - df(tr) - df (error)

22. What is the role of a master black belt?
No -- only if the process is also capable.
3.4 (assuming 1.5 sigma shift in the mean)
To mentor/coach (and sometimes train) black belts.
The cycle time required to meet demand.

23. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Deming.
No -- the variation also has to be random and "expected."
Walter A. Shewhart
Blame.

24. When is Cpk used?
The House of Quality.
Prevention and appraisal costs are balanced against internal and external failure.
To monitor a process when measurement by variables is used.
To do a capability study for a non-centered process.

25. DOE
X-bar-bar
Because the mean and standard deviation are independent of each other.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Someone who is consistently against virtually everything.

26. Based on what principal can we use the normal distribution assumptions for SPC?
Consumer risk.
Central Limit Theorem
If the Response vs. Levels graph if the response lines are not parallel (crossing)
The target number of standard deviations from the mean for specifications.

27. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
The House of Quality.
=sqrt((p*(1-p)/n)
Lean (or JIT).
The number of standard deviations some value is from the mean.

28. Cause and Effect Diagrams
Variable.
Attribute
Method developed by Ishikawa to graphically display the causes of any given problem
Sampling for SPC is done real time.

29. Define takt time.
Brand image.
Mean time to failure.
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:
The cycle time required to meet demand.

30. What is DPMO?
Can't tell without a Range chart.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Defects Per Million Opportunities

31. In the Service Quality Gap Model - what is Gap 5?
Before production starts
The gap between what customers expect and the service they receive.
A tool that shows performance along key dimensions all at once.
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).

32. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Conformance to specifications.
The degree to which a product meets pre-established standards.
Mean time to failure.
To be a member of a Six Sigma project team.

33. What do you do when a process is out of control?
A time series plot.
Look for the assignable cause of non-random variation.
10 if Almost impossible to detect
Is what induces the failure

34. Disadvantages of DOE

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35. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
3.4 (assuming 1.5 sigma shift in the mean)
Lower skill requirements - faster - less chance for error.
Walter A. Shewhart
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

36. What is the role of a green belt?
To obtain a certain desirable outcome from the process
Initiated before or at design concept finalization
To be a member of a Six Sigma project team.
Stratify a particular defect type according to logical criteria

37. Explain the difference between technical and functional service quality.
Prevention and appraisal costs are balanced against internal and external failure.
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:
Technical quality is the "what" of the service; functional quality is the "how."
The manager in charge of a process being improved in a Six Sigma project.

38. What are the 5 Ss?
Method developed by Ishikawa to graphically display the causes of any given problem
Technical quality is the "what" of the service; functional quality is the "how."
Sort - Set in Order - Shine - Standardize - Sustain
To monitor a process when measurement by attribute is used.

39. What is Value Stream Mapping?
Lower control limit.
Producer risk.
The gap between what management thinks customers want and what customers really want.
A tool that shows where there is waste in a process.

40. Process occurance ranking
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
A descending order-sorted bar chart with a cumulative percentage line.
Upper control limit.
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).

41. To what does the Six in Six Sigma relate?
Lower control limit.
Inventory = throughput x flow time.
The target number of standard deviations from the mean for specifications.
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:

42. What is the Baldrige Award?
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.
Look for the assignable cause of non-random variation.
The US national quality award.
Through producer/consumer negotiation.

43. What happens to control limits on an SPC chart when sample size is increased?
Represents the behavior of a process
They move closer to the center line.
X-bar-bar
Is what induces the failure

44. What is the center line of a p-chart?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
p-bar - the long-run percent defective.
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
Organize ideas into meaningful categories by recognizing their underlying similarity

45. What graphical tool is used to show the relationship between two numerical variables?
Concluding there has been an effect/change when there has not.
Fitness for use.
= 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
A scatterplot.

46. What are the three main categories of assignable cause?
Shifts - Trends - Repeating patterns - Correlation with known events
The ability of a process to consistently meet customer specifications.
Someone who is consistently against virtually everything.
Workers - machines - materials.

47. Regression Analysis
Financial - customer - internal process - innovation and learning.
Someone who is consistently against virtually everything.
10 if Almost impossible to detect
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

48. Define features.
Lean (or JIT).
A tool that shows performance along key dimensions all at once.
Is the way in which the failure is manifested.
The secondary characteristics of a product; "bells and whistles."

49. What is process capability?
A tool that shows the physical flows through a space.
The ability of a process to consistently meet customer specifications.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The degree to which a product meets pre-established standards.

50. What is Little's Law?
Inventory = throughput x flow time.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Waste.