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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. 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.
Define - measure - analyze - improve - control.
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
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

2. Taguchi's experimental designs are of this type.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Fractional factorial designs (orthogonal arrays)
Used to create frequency distribution tally sheets
10 if Almost impossible to detect

3. What is DPMO?
The primary operating characteristics of a product.
Defects Per Million Opportunities
Supplier - input - process - output - customer.
Observed variation in response is caused by the input

4. What is the center line of an X-bar chart?
The gap between what management thinks customers want and the process specifications.
The gap between what management thinks customers want and what customers really want.
Can't tell without a Range chart.
X-bar-bar

5. Affinity Diagrams
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Organize ideas into meaningful categories by recognizing their underlying similarity
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
Fishbone - cause-and-effect diagram.

6. Process check sheets
Used to create frequency distribution tally sheets
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
QFD
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

7. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
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
The ratio of outputs to inputs; 1-scrap.
Stratify a particular defect type according to logical criteria

8. What are the Five Dimensions of Service Quality?
Waste.
Observed variation in response is caused by the input
Reliability - Assurance - Responsiveness - Tangibles - Empathy
To monitor a process when measurement by variables is used.

9. DOE
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 monitor a process when measurement by attribute is used.
Concluding there has not been an effect/change when there has.
Failure Modes and Effects Analysis

10. What does Crosby say about benchmarking?
To obtain a certain desirable outcome from the process
Stratify a particular defect type according to logical criteria
A scatterplot.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

11. One factor at a time (OFAT)
The gap between what management thinks customers want and what customers really want.
Look for the assignable cause of non-random variation.
The gap between what customers expect and the service they receive.
Observed variation in response is caused by the input

12. What is Kaizen?
Kaoru Ishikawa.
The manager in charge of a process being improved in a Six Sigma project.
Rapid improvement process.
Define - measure - analyze - design - verify.

13. What is a Gantt chart?
A time series plot.
A random variable that summarizes the information from the sample(s).
Blame.
Shows the temporal flow of activities in a project network.

14. What quality tool formally incorporates the voice of the customer?
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
=sqrt(Σ(x-x-bar)^2)/(n-1))
Look for the assignable cause of non-random variation.
QFD

15. Define performance quality.
3.4 (assuming 1.5 sigma shift in the mean)
The primary operating characteristics of a product.
The House of Quality.
Variable.

16. Define features.
= 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
Central Limit Theorem
The secondary characteristics of a product; "bells and whistles."
Used to create frequency distribution tally sheets

17. What is a dashboard?
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
No -- if it is not the same - it can only be worse!
A tool that shows performance along key dimensions all at once.
Lower control limit.

18. Why do you need two control charts for variables SPC?
To mentor/coach (and sometimes train) black belts.
Because the mean and standard deviation are independent of each other.
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).
To monitor a process when measurement by variables is used.

19. What is a network diagram?
Large enough to find two of the attribute - on average.
A diagram that shows the relationships between activities in a project network.
Someone who is consistently against virtually everything.
Waste.

20. Define yield.
The ratio of outputs to inputs; 1-scrap.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Outside.
Through producer/consumer negotiation.

21. What is the Baldrige Award?
The US national quality award.
No -- the variation also has to be random and "expected."
Actual drawings - layouts - maps - etc which show where a defect occurs
Is the way in which the failure is manifested.

22. What are the four perspectives of the Balanced Scorecard?
50%
A tool that shows the physical flows through a space.
10 if Almost impossible to detect
Financial - customer - internal process - innovation and learning.

23. Pareto Analysis
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
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.
Assigns scores to weighted criteria for each project under consideration.

24. What is CTQ?
The ratio of outputs to inputs; 1-scrap.
Critical to quality.
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).
Actual drawings - layouts - maps - etc which show where a defect occurs

25. Disadvantages of DOE

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26. Failure effect
Represents the behavior of a process
100%
Is the consequence of the failure.
A tool that shows performance along key dimensions all at once.

27. Define benchmarking.
Studying firms with the best performance in a particular area.
Large enough to find two of the attribute - on average.
Speed - courtesy - competence - and ease of repair.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

28. What are the four categories of costs in Juran's framework?
It's good -- but it's still out of control!
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Prevention - appraisal - internal failure - external failure.
A tool that shows where there is waste in a process.

29. When yields decrease - what are the two effects on contribution?
Fewer good units to sell - increased variable cost/unit.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
5%
Deming.

30. What is a histogram?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Critical to quality.
What the value of the dependent variable is when the independent variable is zero.
The US national quality award.

31. In a regression - what does the coefficient of the intercept tell you
Is what induces the failure
A diagram that shows the relationships between activities in a project network.
Inventory = throughput x flow time.
What the value of the dependent variable is when the independent variable is zero.

32. How does Juran define quality?
Fitness for use.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
No -- only if the process is also capable.
Mean time to failure.

33. Define takt time.
Failure Modes and Effects Analysis
The cycle time required to meet demand.
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
Observed variation in response is caused by the input

34. What does SIPOC stand for?
The number of standard deviations some value is from the mean.
Supplier - input - process - output - customer.
Variable.
Through producer/consumer negotiation.

35. Simple Regression Analysis (one factor regression model)
= 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
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Define - measure - analyze - improve - control.
Causes that lead to a particular effect.

36. Who developed the fishbone diagram?
Kaoru Ishikawa.
=sqrt((p*(1-p)/n)
Different types of defects are listed (used for Pareto chart)
Stratify a particular defect type according to logical criteria

37. FMEA
The ratio of outputs to inputs; 1-scrap.
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
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
Observed variation in response is caused by the input

38. Define conformance quality.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A tool that shows performance along key dimensions all at once.
The degree to which a product meets pre-established standards.
Defects Per Million Opportunities

39. For what is a p-chart used?
To monitor a process when measurement by variables is used.
X-bar-bar
To manage the Six Sigma project.
To monitor a process when measurement by attribute is used.

40. What is process capability?
They move closer to the center line.
Outside.
The ability of a process to consistently meet customer specifications.
A diagram that shows the relationships between activities in a project network.

41. What is Value Stream Mapping?
Mean time to failure.
A tool that shows where there is waste in a process.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
To do a capability study for a non-centered process.

42. When is Cpk used?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Producer risk.
Fishbone - cause-and-effect diagram.
To do a capability study for a non-centered process.

43. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Lean (or JIT).
Prevention and appraisal costs are balanced against internal and external failure.
It looks to minimize the probability of a failure - or to minimize its effects
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

44. What do you do when a process is out of control?
Represents the behavior of a process
Look for the assignable cause of non-random variation.
The gap between what management thinks customers want and what customers really want.
Waste.

45. Complete this quality phrase: 'Fix the process - not the _____.'
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
No -- if it is not the same - it can only be worse!
Defects Per Million Opportunities
Blame.

46. What is Type II Error?
Supplier - input - process - output - customer.
Concluding there has not been an effect/change when there has.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Upper control limit.

47. What does a project prioritization matrix do?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Conformance to specifications.
Assigns scores to weighted criteria for each project under consideration.
Rapid improvement process.

48. If you have calculated a Cpk - should you also calculate a Cp?
50%
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
5%
Variable.

49. Which type of SPC measurement is more precise - variable or attribute?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Waste.
Variable.
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

50. In the Service Quality Gap Model - what is Gap 3?
Prevention - appraisal - internal failure - external failure.
The gap between specifications and how service is performed.
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
Define - measure - analyze - improve - control.