Test your basic knowledge |

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 center line of a p-chart?
p-bar - the long-run percent defective.
Lean is waste reduction - Six Sigma is variation reduction.
The primary operating characteristics of a product.
Actual drawings - layouts - maps - etc which show where a defect occurs

2. Design of Experiments (DOE) approach
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Blame.
The gap between specifications and how service is performed.

3. Define aesthetic quality.
Pleasing to the senses.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Hold all input variables constant except one. Observe the response as you vary the single input.

4. What is DMADV?
Define - measure - analyze - design - verify.
Lower skill requirements - faster - less chance for error.
It's good -- but it's still out of control!
No -- only if the process is also capable.

5. Failure effect
Mean time to replacement.
Actual drawings - layouts - maps - etc which show where a defect occurs
Upper control limit.
Is the consequence of the failure.

6. What is the role of a black belt?
Method developed by Ishikawa to graphically display the causes of any given problem
99.73%
Is the way in which the failure is manifested.
To manage the Six Sigma project.

7. What is written on the "spines" of a fishbone diagram?
To monitor a process when measurement by attribute is used.
A random variable that summarizes the information from the sample(s).
Supplier - input - process - output - customer.
Causes that lead to a particular effect.

8. What is the 5S model?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Shifts - Trends - Repeating patterns - Correlation with known events
To monitor a process when measurement by variables is used.

9. Define performance quality.
Before production starts
Inventory = throughput x flow time.
The primary operating characteristics of a product.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

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

11. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Not necessarily.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Attribute

12. When is Cpk used?
The gap between what is promised and what is delivered.
To do a capability study for a non-centered process.
Lower skill requirements - faster - less chance for error.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

13. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
= yij - y(bar)i --> value minus sum of that treatment (of row)
To obtain a certain desirable outcome from the process
Define - measure - analyze - improve - control.
No -- the variation also has to be random and "expected."

14. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Variable.
The gap between specifications and how service is performed.
Upper control limit.
It's good -- but it's still out of control!

15. TWO-DIMENTIONAL SCATTER PLOT
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
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
Mean time to replacement.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

16. For what is an x-bar chart used?
X-bar-bar
Walter A. Shewhart
To monitor a process when measurement by variables is used.
Shifts - Trends - Repeating patterns - Correlation with known events

17. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Shifts - Trends - Repeating patterns - Correlation with known events
Hold all input variables constant except one. Observe the response as you vary the single input.
95%
Look for the assignable cause of non-random variation.

18. Name the structure associated with Quality Function Deployment.
Variable.
They move closer to the center line.
A time series plot.
The House of Quality.

19. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Conformance to specifications.
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
Represents the behavior of a process
A diagram that shows the relationships between activities in a project network.

20. What is FMEA?
Consumer risk.
Failure Modes and Effects Analysis
Outside.
Defects Per Million Opportunities

21. 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?
False - because each machine will have different natural tolerances.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
F_alpha - df(tr) - df (error)

22. Process occurance ranking
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Lean (or JIT).
They move closer to the center line.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

23. Does it ever make sense to accept a job when a process is incapable?
The cycle time required to meet demand.
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
Pleasing to the senses.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

24. What are the four categories of costs in Juran's framework?
Attribute.
A random variable that summarizes the information from the sample(s).
Studying firms with the best performance in a particular area.
Prevention - appraisal - internal failure - external failure.

25. What quality tool formally incorporates the voice of the customer?
Linearity - normality - homoscedasticity - independence.
Before production starts
A tool that shows the physical flows through a space.
QFD

26. Define yield.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The ratio of outputs to inputs; 1-scrap.
The Japanese national quality award.
Used to create frequency distribution tally sheets

27. What is a network diagram?
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
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
A diagram that shows the relationships between activities in a project network.

28. DFMEA
95%
Fewer good units to sell - increased variable cost/unit.
Sort - Set in Order - Shine - Standardize - Sustain
Initiated before or at design concept finalization

29. Presence of interaction effect
The target number of standard deviations from the mean for specifications.
The secondary characteristics of a product; "bells and whistles."
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
If the Response vs. Levels graph if the response lines are not parallel (crossing)

30. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
Define - measure - analyze - improve - control.
Organize ideas into meaningful categories by recognizing their underlying similarity
If the Response vs. Levels graph if the response lines are not parallel (crossing)

31. A process is operating "in control." Does this mean the customer's requirements are met?
No -- only if the process is also capable.
Attribute
Fishbone - cause-and-effect diagram.
Mean time to failure.

32. List two components of prevention cost.
Concluding there has been an effect/change when there has not.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Organize ideas into meaningful categories by recognizing their underlying similarity
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).

33. Define takt time.
Hold all input variables constant except one. Observe the response as you vary the single input.
They move closer to the center line.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The cycle time required to meet demand.

34. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
99.73%
X-bar-bar
The gap between what is promised and what is delivered.
A tool that shows where there is waste in a process.

35. If you have calculated a Cpk - should you also calculate a Cp?
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
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
A diagram that shows the relationships between activities in a project network.

36. In the Service Quality Gap Model - what is Gap 1?
Producer risk.
Define - measure - analyze - improve - control.
The gap between what management thinks customers want and what customers really want.
The ability of a process to consistently meet customer specifications.

37. Definition of Interaction
Lean (or JIT).
Supplier - input - process - output - customer.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
To mentor/coach (and sometimes train) black belts.

38. What is a run chart?
A time series plot.
Fewer good units to sell - increased variable cost/unit.
The gap between specifications and how service is performed.
Because the mean and standard deviation are independent of each other.

39. One factor at a time (OFAT)
Outside.
Waste.
Hold all input variables constant except one. Observe the response as you vary the single input.
A random variable that summarizes the information from the sample(s).

40. In the Service Quality Gap Model - what is Gap 2?
100%
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The gap between what management thinks customers want and the process specifications.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

41. What is a dashboard?
A tool that shows performance along key dimensions all at once.
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
p-bar - the long-run percent defective.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

42. Define durability.
No -- the variation also has to be random and "expected."
Waste.
Concluding there has been an effect/change when there has not.
Mean time to replacement.

43. Your production process meets customer specifications. Is your process in control?
F_alpha - df(tr) - df (error)
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
Not necessarily.
Large enough to find two of the attribute - on average.

44. Failure Mode
Is the way in which the failure is manifested.
The number of standard deviations some value is from the mean.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
100%

45. To what does the Six in Six Sigma relate?
A tool that shows the physical flows through a space.
Large enough to find two of the attribute - on average.
The target number of standard deviations from the mean for specifications.
Defects Per Million Opportunities

46. Test for Independence
Look for the assignable cause of non-random variation.
=sqrt((p*(1-p)/n)
The gap between what management thinks customers want and what customers really want.
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

47. Defect check sheets
Different types of defects are listed (used for Pareto chart)
QFD
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Through producer/consumer negotiation.

48. If you can only collect categorical data - what type of SPC charting can you do?
Attribute.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Fractional factorial designs (orthogonal arrays)
A tool that shows performance along key dimensions all at once.

49. Risk Priority Number RPN
3.4 (assuming 1.5 sigma shift in the mean)
Outside.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
=sqrt((p*(1-p)/n)

50. Define conformance quality.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
QFD
5%
The degree to which a product meets pre-established standards.