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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. Failure cause
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Waste.
Is what induces the failure

2. What are two other names for an Ishikawa diagram?
Fishbone - cause-and-effect diagram.
Large enough to find two of the attribute - on average.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
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

3. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Outside.
Someone who is consistently against virtually everything.
Variable.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

4. What is a Gantt chart?
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).
= 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
Shows the temporal flow of activities in a project network.
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

5. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Mistake-proofing.
99.73%
Lower skill requirements - faster - less chance for error.
A scatterplot.

6. Define perceived quality (Garvin's framework).
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Brand image.
Studying firms with the best performance in a particular area.
No -- if it is not the same - it can only be worse!

7. Define yield.
Variable.
The Japanese national quality award.
Linearity - normality - homoscedasticity - independence.
The ratio of outputs to inputs; 1-scrap.

8. Risk Priority Number RPN
Variable.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The US national quality award.

9. What quality tool formally incorporates the voice of the customer?
p-bar - the long-run percent defective.
Initiated before or at design concept finalization
To do a capability study for a non-centered process.
QFD

10. Uses of regression - Control
Large enough to find two of the attribute - on average.
Actual drawings - layouts - maps - etc which show where a defect occurs
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
To obtain a certain desirable outcome from the process

11. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
Financial - customer - internal process - innovation and learning.
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
Observed variation in response is caused by the input

12. What is DMADV?
Is what induces the failure
Blame.
Large enough to find two of the attribute - on average.
Define - measure - analyze - design - verify.

13. What is the center line of a p-chart?
Consumer risk.
p-bar - the long-run percent defective.
To manage the Six Sigma project.
No -- if it is not the same - it can only be worse!

14. F value
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
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:
Taguchi
F_alpha - df(tr) - df (error)

15. 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?
To manage the Six Sigma project.
False - because each machine will have different natural tolerances.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
=sqrt(Σ(x-x-bar)^2)/(n-1))

16. Non-random patterns (Run Charts)
Lean (or JIT).
The Japanese national quality award.
Shifts - Trends - Repeating patterns - Correlation with known events
50%

17. In a Z table - what is Z?
The House of Quality.
A time series plot.
The number of standard deviations some value is from the mean.
A tool that shows the physical flows through a space.

18. Daniel Test
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:
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Stratify a particular defect type according to logical criteria
Kaoru Ishikawa.

19. Presence of interaction effect
What the value of the dependent variable is when the independent variable is zero.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Prevention and appraisal costs are balanced against internal and external failure.
Concluding there has not been an effect/change when there has.

20. FMEA
The gap between what management thinks customers want and what customers really want.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
It looks to minimize the probability of a failure - or to minimize its effects
Producer risk.

21. What is the Baldrige Award?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
The US national quality award.
Inventory = throughput x flow time.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

22. What is a Gage R&R?
The Japanese national quality award.
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).
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 customers expect and the service they receive.

23. What does the abbreviation LCL stand for?
Large enough to find two of the attribute - on average.
No -- the variation also has to be random and "expected."
Lower control limit.
They move closer to the center line.

24. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Method developed by Ishikawa to graphically display the causes of any given problem
Linearity - normality - homoscedasticity - independence.
A brainstorming tool that shows the connections between ideas.
95%

25. If you have calculated a Cpk - should you also calculate a Cp?
Large enough to find two of the attribute - on average.
Workers - machines - materials.
The secondary characteristics of a product; "bells and whistles."
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

26. What is Kaizen?
10 for Hazardous without warning 1 for none
Concluding there has not been an effect/change when there has.
QFD
Rapid improvement process.

27. Failure effect
Large enough to find two of the attribute - on average.
Is the consequence of the failure.
The gap between what is promised and what is delivered.
Sampling for SPC is done real time.

28. Process check sheets
Used to create frequency distribution tally sheets
To monitor a process when measurement by attribute is used.
A diagram that shows the relationships between activities in a project network.
A brainstorming tool that shows the connections between ideas.

29. For what is a p-chart used?
68%
Because the mean and standard deviation are independent of each other.
To monitor a process when measurement by attribute is used.
Actual drawings - layouts - maps - etc which show where a defect occurs

30. Histogram by Hand
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Fitness for use.
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
Attribute

31. Define durability.
Mistake-proofing.
Mean time to replacement.
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).
The ability of a process to consistently meet customer specifications.

32. Process occurance ranking
= 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
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
It's good -- but it's still out of control!
3.4 (assuming 1.5 sigma shift in the mean)

33. If a three-stage process has 90% yields at each stage - what is the overall yield?
Is what induces the failure
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
The gap between what is promised and what is delivered.
0.9^3 or 72.9%

34. Define benchmarking.
Studying firms with the best performance in a particular area.
95%
A random variable that summarizes the information from the sample(s).
0.9^3 or 72.9%

35. One factor at a time (OFAT)
Prevention and appraisal costs are balanced against internal and external failure.
Mean time to replacement.
Hold all input variables constant except one. Observe the response as you vary the single input.
It looks to minimize the probability of a failure - or to minimize its effects

36. Which quality guru developed the concept of loss to society?
Taguchi
Mean time to replacement.
A tool that shows performance along key dimensions all at once.
Fractional factorial designs (orthogonal arrays)

37. Stratified defect check sheets
Stratify a particular defect type according to logical criteria
Rapid improvement process.
10 if Almost impossible to detect
If the Response vs. Levels graph if the response lines are not parallel (crossing)

38. Defect location check sheets
0.9^3 or 72.9%
5%
Actual drawings - layouts - maps - etc which show where a defect occurs
To monitor a process when measurement by attribute is used.

39. TWO-DIMENTIONAL SCATTER PLOT
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Inventory = throughput x flow time.
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
They move closer to the center line.

40. Define serviceability.
The primary operating characteristics of a product.
Speed - courtesy - competence - and ease of repair.
To do a capability study for a non-centered process.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

41. Residual
Prevention and appraisal costs are balanced against internal and external failure.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Before production starts
A tool that shows performance along key dimensions all at once.

42. What type of risk is associated with Type II Error?
A diagram that shows the relationships between activities in a project network.
The secondary characteristics of a product; "bells and whistles."
Consumer risk.
68%

43. Affinity Diagrams
Central Limit Theorem
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Studying firms with the best performance in a particular area.

44. In a regression - what does the p value of F tell you?
To mentor/coach (and sometimes train) black belts.
Attribute
Sampling for SPC is done real time.
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).

45. What is Type 1 Error?
3.4 (assuming 1.5 sigma shift in the mean)
Concluding there has been an effect/change when there has not.
Studying firms with the best performance in a particular area.
The primary operating characteristics of a product.

46. If you can only collect categorical data - what type of SPC charting can you do?
A random variable that summarizes the information from the sample(s).
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Attribute.
Outside.

47. In a regression - what does the coefficient of the intercept tell you
Consumer risk.
What the value of the dependent variable is when the independent variable is zero.
= yij - y(bar)i --> value minus sum of that treatment (of row)
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

48. Regression Analysis
Is what induces the failure
Outside.
Controlling quality at the source.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

49. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
Waste.
Producer 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

50. The Test Statistic (TS)
False - because each machine will have different natural tolerances.
Fewer good units to sell - increased variable cost/unit.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
A random variable that summarizes the information from the sample(s).