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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. What is an affinity diagram?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
A brainstorming tool that shows the connections between ideas.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Is the way in which the failure is manifested.

2. What is the role of a master black belt?
0.9^3 or 72.9%
A tool that shows where there is waste in a process.
To mentor/coach (and sometimes train) black belts.
10 if Almost impossible to detect

3. Non-random patterns (Run Charts)
Shifts - Trends - Repeating patterns - Correlation with known events
Fractional factorial designs (orthogonal arrays)
Method developed by Ishikawa to graphically display the causes of any given problem
The ratio of outputs to inputs; 1-scrap.

4. If a three-stage process has 90% yields at each stage - what is the overall yield?
A tool that shows performance along key dimensions all at once.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
0.9^3 or 72.9%
A tool that shows where there is waste in a process.

5. What is muda
Waste.
Actual drawings - layouts - maps - etc which show where a defect occurs
Lower skill requirements - faster - less chance for error.
Shows the temporal flow of activities in a project network.

6. Failure cause
Taguchi
Studying firms with the best performance in a particular area.
False - because each machine will have different natural tolerances.
Is what induces the failure

7. Risk Priority Number RPN
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
5%
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Walter A. Shewhart

8. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Technical quality is the "what" of the service; functional quality is the "how."
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Large enough to find two of the attribute - on average.
Attribute

9. What do you do when a process is out of control?
=sqrt((p*(1-p)/n)
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Look for the assignable cause of non-random variation.
Blame.

10. What is the difference between Lean and Six Sigma?
Controlling quality at the source.
Lean is waste reduction - Six Sigma is variation reduction.
Fewer good units to sell - increased variable cost/unit.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

11. For what is a p-chart used?
= yij - y(bar)i --> value minus sum of that treatment (of row)
To monitor a process when measurement by attribute is used.
Not necessarily.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

12. List two components of prevention cost.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Initiated before or at design concept finalization
Prevention - appraisal - internal failure - external failure.
Rapid improvement process.

13. In a Z table - what is Z?
Brand image.
The number of standard deviations some value is from the mean.
=sqrt(Σ(x-x-bar)^2)/(n-1))
QFD

14. One factor at a time (OFAT)
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Defects Per Million Opportunities
Before production starts
Hold all input variables constant except one. Observe the response as you vary the single input.

15. What is a histogram?
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:
Walter A. Shewhart
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
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.

16. What is Value Stream Mapping?
Attribute
Producer risk.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
A tool that shows where there is waste in a process.

17. What is the center line of a p-chart?
Inventory = throughput x flow time.
Lean (or JIT).
Outside.
p-bar - the long-run percent defective.

18. Who is a process owner?
Scrap - rework - retest - downtime - yield losses - disposition costs.
A brainstorming tool that shows the connections between ideas.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
The manager in charge of a process being improved in a Six Sigma project.

19. FMEA
It looks to minimize the probability of a failure - or to minimize its effects
Is what induces the failure
Kaoru Ishikawa.
The primary operating characteristics of a product.

20. What is Kaizen?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The primary operating characteristics of a product.
Rapid improvement process.
Waste.

21. Residual
Inventory = throughput x flow time.
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).
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
A tool that shows performance along key dimensions all at once.

22. Regression
Represents the behavior of a process
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Large enough to find two of the attribute - on average.

23. What is process capability?
5%
The ability of a process to consistently meet customer specifications.
Assigns scores to weighted criteria for each project under consideration.
Attribute

24. In the Service Quality Gap Model - what is Gap 4?
Define - measure - analyze - design - verify.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
The gap between what is promised and what is delivered.
Pleasing to the senses.

25. Your production process meets customer specifications. Is your process in control?
Is the way in which the failure is manifested.
Not necessarily.
10 for Hazardous without warning 1 for none
Prevention - appraisal - internal failure - external failure.

26. Define serviceability.
Speed - courtesy - competence - and ease of repair.
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
0.9^3 or 72.9%
Attribute.

27. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
False - because each machine will have different natural tolerances.
They move closer to the center line.
100%
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

28. What is a CAVE man?
Mean time to replacement.
Someone who is consistently against virtually everything.
Lower skill requirements - faster - less chance for error.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

29. What are the four regression assumptions?
Defects Per Million Opportunities
Linearity - normality - homoscedasticity - independence.
3.4 (assuming 1.5 sigma shift in the mean)
Hold all input variables constant except one. Observe the response as you vary the single input.

30. You have been plotting sample means on an x-bar chart and all points indicate normal - expected variation. Is the process in control?

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31. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
Critical to quality.
5%
Technical quality is the "what" of the service; functional quality is the "how."

32. When yields decrease - what are the two effects on contribution?
Fewer good units to sell - increased variable cost/unit.
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
The gap between what management thinks customers want and the process specifications.

33. Advantages of DOE
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
Before production starts
Reliability - Assurance - Responsiveness - Tangibles - Empathy

34. Complete this quality phrase: 'Fix the process - not the _____.'
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
A tool that shows where there is waste in a process.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Blame.

35. What is the Baldrige Award?
Look for the assignable cause of non-random variation.
To monitor a process when measurement by variables is used.
The US national quality award.
Outside.

36. What is the role of a green belt?
Linearity - normality - homoscedasticity - independence.
50%
Failure Modes and Effects Analysis
To be a member of a Six Sigma project team.

37. Defect check sheets
Fitness for use.
To manage the Six Sigma project.
Different types of defects are listed (used for Pareto chart)
The gap between what management thinks customers want and the process specifications.

38. What does SIPOC stand for?
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:
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Actual drawings - layouts - maps - etc which show where a defect occurs
Supplier - input - process - output - customer.

39. List two components of internal failure.
Critical to quality.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Scrap - rework - retest - downtime - yield losses - disposition costs.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

40. List two components of external failure.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Stratify a particular defect type according to logical criteria
Supplier - input - process - output - customer.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

41. Defect location check sheets
Actual drawings - layouts - maps - etc which show where a defect occurs
50%
Mean time to failure.
The House of Quality.

42. Who first studied randomness in industrial processes
Shifts - Trends - Repeating patterns - Correlation with known events
Walter A. Shewhart
The manager in charge of a process being improved in a Six Sigma project.
To mentor/coach (and sometimes train) black belts.

43. Detection Criteria Ranking
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
10 if Almost impossible to detect
Prevention - appraisal - internal failure - external failure.
Failure Modes and Effects Analysis

44. Define performance quality.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Attribute.
The primary operating characteristics of a product.

45. Affinity Diagrams
Not necessarily.
To do a capability study for a non-centered process.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Through producer/consumer negotiation.

46. FMEA
The number of standard deviations some value is from the mean.
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
3.4 (assuming 1.5 sigma shift in the mean)
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.

47. In a regression - what does the coefficient of the intercept tell you
Consumer risk.
Because the mean and standard deviation are independent of each other.
What the value of the dependent variable is when the independent variable is zero.
A tool that shows performance along key dimensions all at once.

48. Effect ranking (Severity of the Defect)
A diagram that shows the relationships between activities in a project network.
10 for Hazardous without warning 1 for none
Variable.
Waste.

49. Based on what principal can we use the normal distribution assumptions for SPC?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
10 if Almost impossible to detect
Central Limit Theorem
Financial - customer - internal process - innovation and learning.

50. What is DPMO?
Blame.
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
Defects Per Million Opportunities
Mean time to failure.