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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. A process is operating "in control." Does this mean the customer's requirements are met?
No -- only if the process is also capable.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
X-bar-bar
Define - measure - analyze - design - verify.

2. What is the center line of an X-bar chart?
X-bar-bar
The gap between specifications and how service is performed.
Someone who is consistently against virtually everything.
Prevention and appraisal costs are balanced against internal and external failure.

3. What is the Baldrige Award?
A random variable that summarizes the information from the sample(s).
QFD
The US national quality award.
Kaoru Ishikawa.

4. 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
To manage the Six Sigma project.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Large enough to find two of the attribute - on average.

5. For what is a p-chart used?
To mentor/coach (and sometimes train) black belts.
Mean time to replacement.
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.

6. What is the difference between Lean and Six Sigma?
Lean is waste reduction - Six Sigma is variation reduction.
Stratify a particular defect type according to logical criteria
Shifts - Trends - Repeating patterns - Correlation with known events
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

7. List two appraisal costs.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
The ratio of outputs to inputs; 1-scrap.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
To manage the Six Sigma project.

8. 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?
Speed - courtesy - competence - and ease of repair.
Inventory = throughput x flow time.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
False - because each machine will have different natural tolerances.

9. What are the three main categories of assignable cause?
Walter A. Shewhart
Workers - machines - materials.
= 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
Can't tell without a Range chart.

10. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Scrap - rework - retest - downtime - yield losses - disposition costs.
=sqrt(Σ(x-x-bar)^2)/(n-1))
The House of Quality.
Outside.

11. Risk Priority Number RPN
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
50%
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

12. Histogram by Hand
Fewer good units to sell - increased variable cost/unit.
Speed - courtesy - competence - and ease of repair.
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
Define - measure - analyze - improve - control.

13. What does DMAIC stand for?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Define - measure - analyze - improve - control.
The gap between what is promised and what is delivered.
Used to create frequency distribution tally sheets

14. What are the 5 Ss?
Deming.
Sort - Set in Order - Shine - Standardize - Sustain
A brainstorming tool that shows the connections between ideas.
A diagram that shows the relationships between activities in a project network.

15. ANOVA

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16. Definition of Interaction
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
No -- only if the process is also capable.
A descending order-sorted bar chart with a cumulative percentage line.
Walter A. Shewhart

17. Based on what principal can we use the normal distribution assumptions for SPC?
To mentor/coach (and sometimes train) black belts.
Central Limit Theorem
Consumer risk.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

18. What size should samples be for attribute SPC?
Large enough to find two of the attribute - on average.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
The gap between what is promised and what is delivered.

19. List two components of internal failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Fewer good units to sell - increased variable cost/unit.
False - because each machine will have different natural tolerances.
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.

20. List two components of prevention cost.
The ratio of outputs to inputs; 1-scrap.
99.73%
Variable.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

21. Effect ranking (Severity of the Defect)
The gap between what customers expect and the service they receive.
10 for Hazardous without warning 1 for none
Sampling for SPC is done real time.
Observed variation in response is caused by the input

22. Complete this quality phrase: 'Fix the process - not the _____.'
No -- only if the process is also capable.
False - because each machine will have different natural tolerances.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Blame.

23. TWO-DIMENTIONAL SCATTER PLOT
To do a capability study for a non-centered process.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Not necessarily.
Assigns scores to weighted criteria for each project under consideration.

24. Define features.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The secondary characteristics of a product; "bells and whistles."
The number of standard deviations some value is from the mean.
Mean time to replacement.

25. What are the Five Dimensions of Service Quality?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
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.
Producer risk.
The number of standard deviations some value is from the mean.

26. Failure cause
The number of standard deviations some value is from the mean.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Is what induces the failure
Hold all input variables constant except one. Observe the response as you vary the single input.

27. What is a Pareto chart?
A descending order-sorted bar chart with a cumulative percentage line.
The ability of a process to consistently meet customer specifications.
A tool that shows where there is waste in a process.
Actual drawings - layouts - maps - etc which show where a defect occurs

28. Define product reliability.
Variable.
Technical quality is the "what" of the service; functional quality is the "how."
Mean time to failure.
Concluding there has not been an effect/change when there has.

29. What is DPMO?
Hold all input variables constant except one. Observe the response as you vary the single input.
Shifts - Trends - Repeating patterns - Correlation with known events
Defects Per Million Opportunities
Variable.

30. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
An assertion or conjecture concerning one or more populations
No -- the variation also has to be random and "expected."
Prevention and appraisal costs are balanced against internal and external failure.
A random variable that summarizes the information from the sample(s).

31. What is written on the "spines" of a fishbone diagram?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A diagram that shows the relationships between activities in a project network.
An assertion or conjecture concerning one or more populations
Causes that lead to a particular effect.

32. Defect check sheets
Technical quality is the "what" of the service; functional quality is the "how."
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
A time series plot.
Different types of defects are listed (used for Pareto chart)

33. What is a run chart?
95%
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
A time series plot.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

34. What do you do when a process is out of control?
3.4 (assuming 1.5 sigma shift in the mean)
Look for the assignable cause of non-random variation.
False - because each machine will have different natural tolerances.
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).

35. In Juran's Cost of Quality model - which categories of costs balance which other categories?
A random variable that summarizes the information from the sample(s).
Prevention and appraisal costs are balanced against internal and external failure.
Critical to quality.
Inventory = throughput x flow time.

36. Residual
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Lean (or JIT).
No -- the variation also has to be random and "expected."
Blame.

37. Why do you need two control charts for variables SPC?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Because the mean and standard deviation are independent of each other.
Inventory = throughput x flow 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:

38. Define takt time.
Scrap - rework - retest - downtime - yield losses - disposition costs.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
The gap between what management thinks customers want and the process specifications.
The cycle time required to meet demand.

39. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Central Limit Theorem
Lean is waste reduction - Six Sigma is variation reduction.
Shows the temporal flow of activities in a project network.
Variable.

40. What happens to control limits on an SPC chart when sample size is increased?
Fishbone - cause-and-effect diagram.
To manage the Six Sigma project.
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).
They move closer to the center line.

41. Process occurance ranking
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
10 if Almost impossible to detect
QFD
Method developed by Ishikawa to graphically display the causes of any given problem

42. Manual Test for Nomality
The gap between what management thinks customers want and what customers really want.
Conformance to specifications.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

43. Disadvantages of DOE

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44. Test for constant variance
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Prevention and appraisal costs are balanced against internal and external failure.
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.
X-bar-bar

45. Define conformance quality.
The degree to which a product meets pre-established standards.
Large enough to find two of the attribute - on average.
No -- if it is not the same - it can only be worse!
The gap between what management thinks customers want and what customers really want.

46. In a regression - what does the p value of F tell you?
The gap between what management thinks customers want and what customers really want.
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).
The House of Quality.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

47. What is the role of a green belt?
The cycle time required to meet demand.
Inventory = throughput x flow time.
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
To be a member of a Six Sigma project team.

48. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Mistake-proofing.
68%
Financial - customer - internal process - innovation and learning.
It looks to minimize the probability of a failure - or to minimize its effects

49. How does Juran define quality?
The secondary characteristics of a product; "bells and whistles."
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
Fitness for use.
Linearity - normality - homoscedasticity - independence.

50. One factor at a time (OFAT)
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."
Deming.
Workers - machines - materials.