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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 the role of a green belt?
50%
The number of standard deviations some value is from the mean.
A tool that shows the physical flows through a space.
To be a member of a Six Sigma project team.

2. Define benchmarking.
The gap between what customers expect and the service they receive.
Lean is waste reduction - Six Sigma is variation reduction.
Studying firms with the best performance in a particular area.
A tool that shows performance along key dimensions all at once.

3. Define durability.
Lean is waste reduction - Six Sigma is variation reduction.
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
Shifts - Trends - Repeating patterns - Correlation with known events
Mean time to replacement.

4. What graphical tool is used to show the relationship between two numerical variables?
X-bar-bar
= yij - y(bar)i --> value minus sum of that treatment (of row)
Workers - machines - materials.
A scatterplot.

5. What is Type 1 Error?
50%
The number of standard deviations some value is from the mean.
Concluding there has been an effect/change when there has not.
Pleasing to the senses.

6. Defect check sheets
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
A descending order-sorted bar chart with a cumulative percentage line.
Outside.
Different types of defects are listed (used for Pareto chart)

7. List two components of internal failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Linearity - normality - homoscedasticity - independence.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Producer risk.

8. In a Z table - what is Z?
10 if Almost impossible to detect
=sqrt((p*(1-p)/n)
Concluding there has been an effect/change when there has not.
The number of standard deviations some value is from the mean.

9. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
Different types of defects are listed (used for Pareto chart)
The primary operating characteristics of a product.
Large enough to find two of the attribute - on average.

10. DFMEA
100%
Represents the behavior of a process
Variable.
Initiated before or at design concept finalization

11. Daniel Test
QFD
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:
Fractional factorial designs (orthogonal arrays)
Not necessarily.

12. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
3.4 (assuming 1.5 sigma shift in the mean)
95%
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Failure Modes and Effects Analysis

13. What is process capability?
The ability of a process to consistently meet customer specifications.
To manage the Six Sigma project.
Inventory = throughput x flow time.
Before production starts

14. Failure effect
Is the consequence of the failure.
The cycle time required to meet demand.
Taguchi
p-bar - the long-run percent defective.

15. Taguchi's experimental designs are of this type.
Linearity - normality - homoscedasticity - independence.
The manager in charge of a process being improved in a Six Sigma project.
Fractional factorial designs (orthogonal arrays)
Speed - courtesy - competence - and ease of repair.

16. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Fishbone - cause-and-effect diagram.
No -- the variation also has to be random and "expected."
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
An assertion or conjecture concerning one or more populations

17. 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).
Blame.
Deming.

18. What is a Gantt chart?
Shows the temporal flow of activities in a project network.
100%
If the Response vs. Levels graph if the response lines are not parallel (crossing)
The number of standard deviations some value is from the mean.

19. What are the three main categories of assignable cause?
To be a member of a Six Sigma project team.
The primary operating characteristics of a product.
Organize ideas into meaningful categories by recognizing their underlying similarity
Workers - machines - materials.

20. Presence of interaction effect
Central Limit Theorem
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Consumer risk.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

21. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Taguchi
Technical quality is the "what" of the service; functional quality is the "how."
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
68%

22. Regression
=sqrt((p*(1-p)/n)
Workers - machines - materials.
Represents the behavior of a process
To mentor/coach (and sometimes train) black belts.

23. What is the formula for standard deviation?
Inventory = throughput x flow time.
Fitness for use.
Workers - machines - materials.
=sqrt(Σ(x-x-bar)^2)/(n-1))

24. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
The degree to which a product meets pre-established standards.
It's good -- but it's still out of control!
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Variable.

25. What is a CAVE man?
Someone who is consistently against virtually everything.
An assertion or conjecture concerning one or more populations
Fishbone - cause-and-effect diagram.
Because the mean and standard deviation are independent of each other.

26. If a three-stage process has 90% yields at each stage - what is the overall yield?
Is what induces the failure
3.4 (assuming 1.5 sigma shift in the mean)
0.9^3 or 72.9%
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

27. Residual(eij)
Assigns scores to weighted criteria for each project under consideration.
A random variable that summarizes the information from the sample(s).
= yij - y(bar)i --> value minus sum of that treatment (of row)
To do a capability study for a non-centered process.

28. What is DMADV?
Define - measure - analyze - design - verify.
To do a capability study for a non-centered process.
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).
Is what induces the failure

29. In the Service Quality Gap Model - what is Gap 1?
The gap between what management thinks customers want and what customers really want.
Inventory = throughput x flow time.
Deming.
The gap between what management thinks customers want and the process specifications.

30. What does SIPOC stand for?
Sampling for SPC is done real time.
Supplier - input - process - output - customer.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

31. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Variable.
Walter A. Shewhart
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Prevention and appraisal costs are balanced against internal and external failure.

32. What percentage of a normal distribution lies above the mean?
To monitor a process when measurement by attribute is used.
Shifts - Trends - Repeating patterns - Correlation with known events
50%
The US national quality award.

33. Define yield.
Failure Modes and Effects Analysis
Variable.
The ratio of outputs to inputs; 1-scrap.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

34. What is an affinity diagram?
Is the consequence of the failure.
Can't tell without a Range chart.
A brainstorming tool that shows the connections between ideas.
The gap between what customers expect and the service they receive.

35. Define performance quality.
A tool that shows performance along key dimensions all at once.
= yij - y(bar)i --> value minus sum of that treatment (of row)
The primary operating characteristics of a product.
Observed variation in response is caused by the input

36. Who developed the fishbone diagram?
Kaoru Ishikawa.
The number of standard deviations some value is from the mean.
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

37. What are the four perspectives of the Balanced Scorecard?
Financial - customer - internal process - innovation and learning.
A tool that shows performance along key dimensions all at once.
Upper control limit.
Variable.

38. Design of Experiments (DOE) approach
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).
Represents the behavior of a process
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Assigns scores to weighted criteria for each project under consideration.

39. For what is an x-bar chart used?
Initiated before or at design concept finalization
Not necessarily.
To monitor a process when measurement by variables is used.
The cycle time required to meet demand.

40. FMEA
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Is the consequence of the failure.
The gap between what is promised and what is delivered.
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

41. One factor at a time (OFAT)
Observed variation in response is caused by the input
Is what induces the failure
50%
The degree to which a product meets pre-established standards.

42. Manual Test for Nomality
Represents the behavior of a process
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
3.4 (assuming 1.5 sigma shift in the mean)
Linearity - normality - homoscedasticity - independence.

43. What does the abbreviation LCL stand for?
Lower control limit.
Inventory = throughput x flow time.
Lower skill requirements - faster - less chance for error.
Mistake-proofing.

44. What does the abbreviation UCL stand for?
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.
Upper control limit.
100%
Fractional factorial designs (orthogonal arrays)

45. List two components of external failure.
To monitor a process when measurement by attribute is used.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
10 if Almost impossible to detect
The primary operating characteristics of a product.

46. What is muda
Sampling for SPC is done real 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:
Fitness for use.
Waste.

47. Who first studied randomness in industrial processes
Conformance to specifications.
Assigns scores to weighted criteria for each project under consideration.
Mean time to failure.
Walter A. Shewhart

48. Name the structure associated with Quality Function Deployment.
The House of Quality.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Financial - customer - internal process - innovation and learning.
3.4 (assuming 1.5 sigma shift in the mean)

49. What are the 5 Ss?
= 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
They move closer to the center line.
Sort - Set in Order - Shine - Standardize - Sustain
Lean is waste reduction - Six Sigma is variation reduction.

50. What is the difference between the way sampling is done for SPC and for acceptance sampling?
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
Sampling for SPC is done real time.
0.9^3 or 72.9%
No -- the variation also has to be random and "expected."