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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. Definition of Interaction
Failure Modes and Effects Analysis
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Prevention - appraisal - internal failure - external failure.
Controlling quality at the source.

2. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
The Japanese national quality award.
Mistake-proofing.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Lower skill requirements - faster - less chance for error.

3. Defect check sheets
Different types of defects are listed (used for Pareto chart)
It looks to minimize the probability of a failure - or to minimize its effects
Lower control limit.
A scatterplot.

4. Based on what principal can we use the normal distribution assumptions for SPC?
Stratify a particular defect type according to logical criteria
Central Limit Theorem
The cycle time required to meet demand.
The secondary characteristics of a product; "bells and whistles."

5. What is process capability?
X-bar-bar
The ability of a process to consistently meet customer specifications.
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
Before production starts

6. What is Jidoka?
Workers - machines - materials.
The target number of standard deviations from the mean for specifications.
Outside.
Controlling quality at the source.

7. Manual Test for Nomality
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).
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
They move closer to the center line.
The House of Quality.

8. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Organize ideas into meaningful categories by recognizing their underlying similarity
10 for Hazardous without warning 1 for none
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

9. What is a Gantt chart?
Technical quality is the "what" of the service; functional quality is the "how."
Represents the behavior of a process
Shows the temporal flow of activities in a project network.
Waste.

10. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
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
Variable.
Concluding there has been an effect/change when there has not.
A brainstorming tool that shows the connections between ideas.

11. Process occurance ranking
Concluding there has been an effect/change when there has not.
Taguchi
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

12. What happens to control limits on an SPC chart when sample size is increased?
They move closer to the center line.
Look for the assignable cause of non-random variation.
Attribute
Conformance to specifications.

13. What type of risk is associated with Type II Error?
Attribute.
Not necessarily.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Consumer risk.

14. Taguchi's experimental designs are of this type.
Stratify a particular defect type according to logical criteria
QFD
A tool that shows where there is waste in a process.
Fractional factorial designs (orthogonal arrays)

15. Daniel Test
Controlling quality at the source.
The cycle time required to meet demand.
The secondary characteristics of a product; "bells and whistles."
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:

16. Define aesthetic quality.
QFD
Prevention - appraisal - internal failure - external failure.
=sqrt((p*(1-p)/n)
Pleasing to the senses.

17. What is a CAVE man?
Someone who is consistently against virtually everything.
A tool that shows where there is waste in a process.
Concluding there has been an effect/change when there has not.
100%

18. If you have calculated a Cpk - should you also calculate a Cp?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Mean time to failure.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
No -- the variation also has to be random and "expected."

19. Pareto Analysis
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
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
Used to create frequency distribution tally sheets
Prevention and appraisal costs are balanced against internal and external failure.

20. What are the Five Dimensions of Service Quality?
Is the consequence of the failure.
No -- if it is not the same - it can only be worse!
Fitness for use.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

21. What is CTQ?
Shifts - Trends - Repeating patterns - Correlation with known events
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Critical to quality.
Is what induces the failure

22. What is the Baldrige Award?
Brand image.
Lean (or JIT).
The US national quality award.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

23. What is the formula for the standard deviation of a proportion?
Attribute.
QFD
=sqrt((p*(1-p)/n)
Critical to quality.

24. What do you do when a process is out of control?
Look for the assignable cause of non-random variation.
They move closer to the center line.
It looks to minimize the probability of a failure - or to minimize its effects
= 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

25. Define durability.
Rapid improvement process.
Stratify a particular defect type according to logical criteria
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Mean time to replacement.

26. 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?
They move closer to the center line.
False - because each machine will have different natural tolerances.
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:
Central Limit Theorem

27. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Kaoru Ishikawa.
Lean is waste reduction - Six Sigma is variation reduction.
Outside.

28. What type of risk is associated with Type 1 Error?
The ability of a process to consistently meet customer specifications.
Producer risk.
False - because each machine will have different natural tolerances.
Stratify a particular defect type according to logical criteria

29. What is a Pareto chart?
A random variable that summarizes the information from the sample(s).
Actual drawings - layouts - maps - etc which show where a defect occurs
Define - measure - analyze - design - verify.
A descending order-sorted bar chart with a cumulative percentage line.

30. FMEA
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
A tool that shows the physical flows through a space.
To manage the Six Sigma project.
It looks to minimize the probability of a failure - or to minimize its effects

31. Failure effect
Is the consequence of the failure.
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
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Taguchi

32. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
Assigns scores to weighted criteria for each project under consideration.
100%
=sqrt((p*(1-p)/n)
Because the mean and standard deviation are independent of each other.

33. Risk Priority Number RPN
X-bar-bar
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Central Limit Theorem
Actual drawings - layouts - maps - etc which show where a defect occurs

34. What graphical tool is used to show the relationship between two numerical variables?
Upper control limit.
Lower control limit.
Fractional factorial designs (orthogonal arrays)
A scatterplot.

35. Which quality guru developed the concept of loss to society?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Taguchi
To monitor a process when measurement by attribute is used.
Prevention - appraisal - internal failure - external failure.

36. For what is a p-chart used?
To monitor a process when measurement by attribute is used.
The gap between what management thinks customers want and the process specifications.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
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:

37. Effect ranking (Severity of the Defect)
10 for Hazardous without warning 1 for none
Shows the temporal flow of activities in a project network.
A tool that shows where there is waste in a process.
What the value of the dependent variable is when the independent variable is zero.

38. What is written on the "spines" of a fishbone diagram?
Causes that lead to a particular effect.
To monitor a process when measurement by attribute is used.
Different types of defects are listed (used for Pareto chart)
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

39. What is Type II Error?
It looks to minimize the probability of a failure - or to minimize its effects
Concluding there has not been an effect/change when there has.
Outside.
Assigns scores to weighted criteria for each project under consideration.

40. The Test Statistic (TS)
Outside.
A random variable that summarizes the information from the sample(s).
A scatterplot.
Sort - Set in Order - Shine - Standardize - Sustain

41. Design of Experiments (DOE) approach
A random variable that summarizes the information from the sample(s).
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Fractional factorial designs (orthogonal arrays)

42. ANOVA

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43. What is the center line of an X-bar chart?
X-bar-bar
A scatterplot.
To mentor/coach (and sometimes train) black belts.
Mean time to replacement.

44. If a three-stage process has 90% yields at each stage - what is the overall yield?
=sqrt((p*(1-p)/n)
0.9^3 or 72.9%
They move closer to the center line.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

45. What is the center line of a p-chart?
p-bar - the long-run percent defective.
The ability of a process to consistently meet customer specifications.
Is the way in which the failure is manifested.
Prevention and appraisal costs are balanced against internal and external failure.

46. In a Z table - what is Z?
A diagram that shows the relationships between activities in a project network.
Mean time to failure.
The number of standard deviations some value is from the mean.
50%

47. Stratified defect check sheets
Linearity - normality - homoscedasticity - independence.
The gap between what customers expect and the service they receive.
Financial - customer - internal process - innovation and learning.
Stratify a particular defect type according to logical criteria

48. What is a Gage R&R?
No -- if it is not the same - it can only be worse!
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
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).
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

49. Define takt time.
The cycle time required to meet demand.
3.4 (assuming 1.5 sigma shift in the mean)
Variable.
Used to create frequency distribution tally sheets

50. What is Kaizen?
The ability of a process to consistently meet customer specifications.
Blame.
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
Rapid improvement process.