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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 quality tool formally incorporates the voice of the customer?
Sampling for SPC is done real time.
A tool that shows where there is waste in a process.
Failure Modes and Effects Analysis
QFD

2. What is Type II Error?
Concluding there has not been an effect/change when there has.
Is the way in which the failure is manifested.
The US national quality award.
=sqrt((p*(1-p)/n)

3. Test for constant variance
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).
Controlling quality at the source.
Through producer/consumer negotiation.
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.

4. Defect location check sheets
10 if Almost impossible to detect
No -- only if the process is also capable.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Actual drawings - layouts - maps - etc which show where a defect occurs

5. What does the abbreviation UCL stand for?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Upper control limit.
X-bar-bar
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

6. What is Value Stream Mapping?
A tool that shows where there is waste in a process.
Blame.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
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

7. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
To monitor a process when measurement by variables is used.
The gap between what management thinks customers want and the process specifications.
Lower skill requirements - faster - less chance for error.
Causes that lead to a particular effect.

8. Define yield.
The ratio of outputs to inputs; 1-scrap.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
QFD
Method developed by Ishikawa to graphically display the causes of any given problem

9. What graphical tool is used to show the relationship between two numerical variables?
It looks to minimize the probability of a failure - or to minimize its effects
Deming.
Mistake-proofing.
A scatterplot.

10. What is Little's Law?
Inventory = throughput x flow time.
Waste.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
A diagram that shows the relationships between activities in a project network.

11. In Juran's Cost of Quality model - which categories of costs balance which other categories?
No -- only if the process is also capable.
Prevention and appraisal costs are balanced against internal and external failure.
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:
Different types of defects are listed (used for Pareto chart)

12. What is process capability?
Lower skill requirements - faster - less chance for error.
Method developed by Ishikawa to graphically display the causes of any given problem
It's good -- but it's still out of control!
The ability of a process to consistently meet customer specifications.

13. Simple Regression Analysis (one factor regression model)
Critical to quality.
To obtain a certain desirable outcome from the process
= 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
No -- the variation also has to be random and "expected."

14. What do you do when a process is out of control?
Define - measure - analyze - design - verify.
Used to create frequency distribution tally sheets
Look for the assignable cause of non-random variation.
A tool that shows the physical flows through a space.

15. Histogram by Hand
Mistake-proofing.
Critical to quality.
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
False - because each machine will have different natural tolerances.

16. In the Service Quality Gap Model - what is Gap 2?
Central Limit Theorem
Initiated before or at design concept finalization
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
The gap between what management thinks customers want and the process specifications.

17. What is a CAVE man?
Someone who is consistently against virtually everything.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
= 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
The target number of standard deviations from the mean for specifications.

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

19. Your production process meets customer specifications. Is your process in control?
A diagram that shows the relationships between activities in a project network.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
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
Not necessarily.

20. Define serviceability.
Outside.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
A scatterplot.
Speed - courtesy - competence - and ease of repair.

21. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
To obtain a certain desirable outcome from the process
The manager in charge of a process being improved in a Six Sigma project.
Failure Modes and Effects Analysis

22. What is DMADV?
Define - measure - analyze - design - verify.
Waste.
Scrap - rework - retest - downtime - yield losses - disposition costs.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

23. What is a spaghetti diagram?
The manager in charge of a process being improved in a Six Sigma project.
Fishbone - cause-and-effect diagram.
A tool that shows the physical flows through a space.
p-bar - the long-run percent defective.

24. What are the three main categories of assignable cause?
Workers - machines - materials.
Lean is waste reduction - Six Sigma is variation reduction.
Define - measure - analyze - improve - control.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

25. What is a run chart?
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).
=sqrt((p*(1-p)/n)
A time series plot.
10 for Hazardous without warning 1 for none

26. Design of Experiments (DOE) approach
Organize ideas into meaningful categories by recognizing their underlying similarity
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
The ratio of outputs to inputs; 1-scrap.

27. In the Service Quality Gap Model - what is Gap 3?
Fishbone - cause-and-effect diagram.
The gap between specifications and how service is performed.
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.
A diagram that shows the relationships between activities in a project network.

28. If you can only collect categorical data - what type of SPC charting can you do?
Consumer risk.
Variable.
Observed variation in response is caused by the input
Attribute.

29. Presence of interaction effect
Define - measure - analyze - improve - control.
A random variable that summarizes the information from the sample(s).
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Used to create frequency distribution tally sheets

30. What quality guru emphasizes management as a system?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Deming.
Through producer/consumer negotiation.
It looks to minimize the probability of a failure - or to minimize its effects

31. Risk Priority Number RPN
Mean time to replacement.
Before production starts
Blame.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

32. What is the center line of a p-chart?
p-bar - the long-run percent defective.
Variable.
Sampling for SPC is done real time.
Method developed by Ishikawa to graphically display the causes of any given problem

33. Who first studied randomness in industrial processes
False - because each machine will have different natural tolerances.
Studying firms with the best performance in a particular area.
Walter A. Shewhart
To manage the Six Sigma project.

34. Which type of SPC measurement is more precise - variable or attribute?
Supplier - input - process - output - customer.
Variable.
Waste.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

35. With Six Sigma capability - how many defects per million opportunities would you see?
3.4 (assuming 1.5 sigma shift in the mean)
The House of Quality.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

36. Define durability.
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 ratio of outputs to inputs; 1-scrap.
Mean time to replacement.
To obtain a certain desirable outcome from the process

37. What does the abbreviation LCL stand for?
Lower control limit.
Rapid improvement process.
The gap between what customers expect and the service they receive.
Hold all input variables constant except one. Observe the response as you vary the single input.

38. Define takt time.
Speed - courtesy - competence - and ease of repair.
The gap between specifications and how service is performed.
They move closer to the center line.
The cycle time required to meet demand.

39. What is the difference between Lean and Six Sigma?
They move closer to the center line.
Lean is waste reduction - Six Sigma is variation reduction.
Causes that lead to a particular effect.
50%

40. Defect check sheets
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
=sqrt(Σ(x-x-bar)^2)/(n-1))
Different types of defects are listed (used for Pareto chart)
Before production starts

41. Uses of regression - Control
Can't tell without a Range chart.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
To obtain a certain desirable outcome from the process
To mentor/coach (and sometimes train) black belts.

42. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Mean time to replacement.
Shows the temporal flow of activities in a project network.
Fractional factorial designs (orthogonal arrays)
No -- the variation also has to be random and "expected."

43. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
Taguchi
Define - measure - analyze - design - verify.
100%
The target number of standard deviations from the mean for specifications.

44. If a Cp shows that a process is not capable - should you calculate Cpk?
Shows the temporal flow of activities in a project network.
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.
No -- if it is not the same - it can only be worse!

45. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
95%
The House of Quality.
The gap between what is promised and what is delivered.
Shows the temporal flow of activities in a project network.

46. What is DPMO?
Kaoru Ishikawa.
It's good -- but it's still out of control!
The gap between what management thinks customers want and what customers really want.
Defects Per Million Opportunities

47. Process occurance ranking
Because the mean and standard deviation are independent of each other.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Sort - Set in Order - Shine - Standardize - Sustain
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

48. List Garvin's eight dimensions of product quality.
Blame.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Lower control limit.
Workers - machines - materials.

49. What are the 5 Ss?
To monitor a process when measurement by attribute is used.
The manager in charge of a process being improved in a Six Sigma project.
3.4 (assuming 1.5 sigma shift in the mean)
Sort - Set in Order - Shine - Standardize - Sustain

50. What is the 5S model?
Look for the assignable cause of non-random variation.
Failure Modes and Effects Analysis
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).
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.