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Six Sigma

Subjects : certifications, six-sigma, business-skills

Instructions:

Answer 50 questions in 15 minutes.
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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. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Before production starts
Not necessarily.
Outside.

2. How are LQL and AQL determined in an acceptance sampling plan?
No -- the variation also has to be random and "expected."
Through producer/consumer negotiation.
10 for Hazardous without warning 1 for none
Someone who is consistently against virtually everything.

3. Defect check sheets
Outside.
The primary operating characteristics of a product.
Different types of defects are listed (used for Pareto chart)
To obtain a certain desirable outcome from the process

4. What is the center line of an X-bar chart?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
A tool that shows performance along key dimensions all at once.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
X-bar-bar

5. Advantages of DOE
Speed - courtesy - competence - and ease of repair.
Represents the behavior of a process
Sampling for SPC is done real time.
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

6. In the Service Quality Gap Model - what is Gap 5?
The gap between what customers expect and the service they receive.
Defects Per Million Opportunities
Represents the behavior of a process
Prevention - appraisal - internal failure - external failure.

7. In the Service Quality Gap Model - what is Gap 4?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Brand image.
The gap between what is promised and what is delivered.
The ability of a process to consistently meet customer specifications.

8. What is the role of a black belt?
Linearity - normality - homoscedasticity - independence.
To manage the Six Sigma project.
Lean is waste reduction - Six Sigma is variation reduction.
The manager in charge of a process being improved in a Six Sigma project.

9. Does it ever make sense to accept a job when a process is incapable?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
The US national quality award.
A random variable that summarizes the information from the sample(s).
Brand image.

10. Affinity Diagrams
Brand image.
68%
X-bar-bar
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

11. In the Service Quality Gap Model - what is Gap 3?
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 specifications and how service is performed.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
To mentor/coach (and sometimes train) black belts.

12. Explain the difference between technical and functional service quality.
False - because each machine will have different natural tolerances.
The House of Quality.
Technical quality is the "what" of the service; functional quality is the "how."
68%

13. Uses of regression - Control
To obtain a certain desirable outcome from the process
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Method developed by Ishikawa to graphically display the causes of any given problem
Lower control limit.

14. What type of risk is associated with Type 1 Error?
Assigns scores to weighted criteria for each project under consideration.
Fewer good units to sell - increased variable cost/unit.
Producer risk.
To do a capability study for a non-centered process.

15. What is a Gantt chart?
Actual drawings - layouts - maps - etc which show where a defect occurs
Shows the temporal flow of activities in a project network.
The US national quality award.
Is the way in which the failure is manifested.

16. Define perceived quality (Garvin's framework).
Prevention - appraisal - internal failure - external failure.
Brand image.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Large enough to find two of the attribute - on average.

17. What type of risk is associated with Type II Error?
The gap between what is promised and what is delivered.
Consumer risk.
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
Walter A. Shewhart

18. Define takt time.
The cycle time required to meet demand.
Upper control limit.
Workers - machines - materials.
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:

19. List two appraisal costs.
Is the consequence of the failure.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Concluding there has not been an effect/change when there has.

20. Define aesthetic quality.
To monitor a process when measurement by variables is used.
5%
Look for the assignable cause of non-random variation.
Pleasing to the senses.

21. Process check sheets
Variable.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Used to create frequency distribution tally sheets

22. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Prevention and appraisal costs are balanced against internal and external failure.
5%
Controlling quality at the source.
Shows the temporal flow of activities in a project network.

23. With Six Sigma capability - how many defects per million opportunities would you see?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
3.4 (assuming 1.5 sigma shift in the mean)
Is the way in which the failure is manifested.
The secondary characteristics of a product; "bells and whistles."

24. Failure cause
Large enough to find two of the attribute - on average.
Is what induces the failure
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

25. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Someone who is consistently against virtually everything.
The cycle time required to meet demand.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
95%

26. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Outside.
Mean time to replacement.
The ratio of outputs to inputs; 1-scrap.

27. What does SIPOC stand for?
X-bar-bar
Supplier - input - process - output - customer.
Taguchi
The gap between what is promised and what is delivered.

28. What is CTQ?
Scrap - rework - retest - downtime - yield losses - disposition costs.
Critical to quality.
Brand image.
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

29. 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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30. What is Jidoka?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The ratio of outputs to inputs; 1-scrap.
50%
Controlling quality at the source.

31. What is a Gage R&R?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Critical to quality.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
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. Daniel Test
Initiated before or at design concept finalization
It looks to minimize the probability of a failure - or to minimize its effects
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:
Workers - machines - materials.

33. What is a network diagram?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
99.73%
Financial - customer - internal process - innovation and learning.
A diagram that shows the relationships between activities in a project network.

34. What is written on the "spines" of a fishbone diagram?
Outside.
Controlling quality at the source.
Rapid improvement process.
Causes that lead to a particular effect.

35. What is the Deming Prize?
The Japanese national quality award.
To be a member of a Six Sigma project team.
Shifts - Trends - Repeating patterns - Correlation with known events
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

36. Defect location check sheets
A brainstorming tool that shows the connections between ideas.
Brand image.
A diagram that shows the relationships between activities in a project network.
Actual drawings - layouts - maps - etc which show where a defect occurs

37. Which quality guru developed the concept of loss to society?
Conformance to specifications.
The cycle time required to meet demand.
Taguchi
Financial - customer - internal process - innovation and learning.

38. List two components of internal failure.
QFD
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Is the consequence of the failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.

39. What is Type 1 Error?
They move closer to the center line.
A random variable that summarizes the information from the sample(s).
Failure Modes and Effects Analysis
Concluding there has been an effect/change when there has not.

40. List two components of prevention cost.
10 if Almost impossible to detect
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
10 for Hazardous without warning 1 for none
Walter A. Shewhart

41. Which type of SPC measurement is more precise - variable or attribute?
3.4 (assuming 1.5 sigma shift in the mean)
Variable.
Represents the behavior of a process
Technical quality is the "what" of the service; functional quality is the "how."

42. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Mean time to replacement.
Attribute
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Variable.

43. Name the structure associated with Quality Function Deployment.
= yij - y(bar)i --> value minus sum of that treatment (of row)
The House of Quality.
A descending order-sorted bar chart with a cumulative percentage line.
Not necessarily.

44. What is a dashboard?
Before production starts
A tool that shows performance along key dimensions all at once.
Blame.
A scatterplot.

45. In the Service Quality Gap Model - what is Gap 1?
Shifts - Trends - Repeating patterns - Correlation with known events
The gap between what management thinks customers want and what customers really want.
To be a member of a Six Sigma project team.
Someone who is consistently against virtually everything.

46. List Garvin's eight dimensions of product quality.
Taguchi
A tool that shows where there is waste in a process.
It looks to minimize the probability of a failure - or to minimize its effects
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

47. If you have calculated a Cpk - should you also calculate a Cp?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Sort - Set in Order - Shine - Standardize - Sustain
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
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

48. What is DPMO?
Defects Per Million Opportunities
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Concluding there has been an effect/change when there has not.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

49. Pareto Analysis
The US national quality award.
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
Linearity - normality - homoscedasticity - independence.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

50. Test for Independence
Controlling quality at the source.
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
Prevention - appraisal - internal failure - external failure.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

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Six Sigma

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