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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. Who is a process owner?
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
X-bar-bar
A brainstorming tool that shows the connections between ideas.
The manager in charge of a process being improved in a Six Sigma project.

2. What is the role of a black belt?
Defects Per Million Opportunities
To manage the Six Sigma project.
The gap between what management thinks customers want and the process specifications.
Technical quality is the "what" of the service; functional quality is the "how."

3. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
The cycle time required to meet demand.
100%
Lower skill requirements - faster - less chance for error.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

4. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Sampling for SPC is done real time.
A time series plot.
The ratio of outputs to inputs; 1-scrap.
Can't tell without a Range chart.

5. What is Kaizen?
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
Rapid improvement process.
Central Limit Theorem
They move closer to the center line.

6. What are two other names for an Ishikawa diagram?
Define - measure - analyze - improve - control.
The House of Quality.
A diagram that shows the relationships between activities in a project network.
Fishbone - cause-and-effect diagram.

7. For what is a p-chart used?
Is the way in which the failure is manifested.
The degree to which a product meets pre-established standards.
To monitor a process when measurement by attribute is used.
Represents the behavior of a process

8. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
No -- only if the process is also capable.
Variable.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
To obtain a certain desirable outcome from the process

9. List two components of external failure.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Define - measure - analyze - improve - control.
Used to create frequency distribution tally sheets
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

10. FMEA
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
=sqrt(Σ(x-x-bar)^2)/(n-1))
Hold all input variables constant except one. Observe the response as you vary the single input.
3.4 (assuming 1.5 sigma shift in the mean)

11. What does Crosby say about benchmarking?
Pleasing to the senses.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Method developed by Ishikawa to graphically display the causes of any given problem
Stratify a particular defect type according to logical criteria

12. What are the four regression assumptions?
10 if Almost impossible to detect
Linearity - normality - homoscedasticity - independence.
A tool that shows the physical flows through a space.
To manage the Six Sigma project.

13. How does Juran define quality?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Financial - customer - internal process - innovation and learning.
QFD
Fitness for use.

14. 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?
Brand image.
Different types of defects are listed (used for Pareto chart)
False - because each machine will have different natural tolerances.
100%

15. Define perceived quality (Garvin's framework).
Mean time to failure.
Brand image.
Central Limit Theorem
Define - measure - analyze - design - verify.

16. Advantages of DOE
Inventory = throughput x flow time.
To manage the Six Sigma project.
Attribute
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

17. Which type of SPC measurement is more precise - variable or attribute?
Variable.
The US national quality 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
A random variable that summarizes the information from the sample(s).

18. The data points on an SPC p-chart of defective percent plot below the mean. Is this good or bad?

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19. What does SIPOC stand for?
Rapid improvement process.
Supplier - input - process - output - customer.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Critical to quality.

20. What does the abbreviation UCL stand for?
Upper control limit.
Consumer risk.
Prevention - appraisal - internal failure - external failure.
Mean time to replacement.

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

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22. What is the Baldrige Award?
The ratio of outputs to inputs; 1-scrap.
The US national quality award.
5%
Stratify a particular defect type according to logical criteria

23. Non-random patterns (Run Charts)
Shifts - Trends - Repeating patterns - Correlation with known events
Hold all input variables constant except one. Observe the response as you vary the single input.
Consumer risk.
They move closer to the center line.

24. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
p-bar - the long-run percent defective.
Attribute
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
A descending order-sorted bar chart with a cumulative percentage line.

25. What is a run chart?
A time series plot.
Someone who is consistently against virtually everything.
Concluding there has not been an effect/change when there has.
The gap between what customers expect and the service they receive.

26. Uses of regression - Control
A tool that shows performance along key dimensions all at once.
Prevention and appraisal costs are balanced against internal and external failure.
To obtain a certain desirable outcome from the process
10 for Hazardous without warning 1 for none

27. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Lower skill requirements - faster - less chance for error.
Outside.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The gap between what management thinks customers want and the process specifications.

28. In a regression - what does the coefficient of the intercept tell you
What the value of the dependent variable is when the independent variable is zero.
Waste.
A time series plot.
A descending order-sorted bar chart with a cumulative percentage line.

29. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
Scrap - rework - retest - downtime - yield losses - disposition costs.
Before production starts
Upper control limit.

30. When yields decrease - what are the two effects on contribution?
To mentor/coach (and sometimes train) black belts.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Fewer good units to sell - increased variable cost/unit.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

31. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Someone who is consistently against virtually everything.
Lower skill requirements - faster - less chance for error.
A scatterplot.
3.4 (assuming 1.5 sigma shift in the mean)

32. DOE
p-bar - the long-run percent defective.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
No -- if it is not the same - it can only be worse!
10 for Hazardous without warning 1 for none

33. With Six Sigma capability - how many defects per million opportunities would you see?
3.4 (assuming 1.5 sigma shift in the mean)
Concluding there has been an effect/change when there has not.
Someone who is consistently against virtually everything.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

34. List two components of internal failure.
Represents the behavior of a process
Speed - courtesy - competence - and ease of repair.
The gap between what is promised and what is delivered.
Scrap - rework - retest - downtime - yield losses - disposition costs.

35. Who first studied randomness in industrial processes
Walter A. Shewhart
No -- only if the process is also capable.
Controlling quality at the source.
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

36. DFMEA
What the value of the dependent variable is when the independent variable is zero.
Before production starts
Initiated before or at design concept finalization
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

37. 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:
Concluding there has been an effect/change when there has not.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Lower skill requirements - faster - less chance for error.

38. If you have calculated a Cpk - should you also calculate a Cp?
Linearity - normality - homoscedasticity - independence.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
= yij - y(bar)i --> value minus sum of that treatment (of row)
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

39. What is the difference between Lean and Six Sigma?
Lean is waste reduction - Six Sigma is variation reduction.
A tool that shows performance along key dimensions all at once.
To be a member of a Six Sigma project team.
Blame.

40. For what is an x-bar chart used?
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
The US national quality award.
To monitor a process when measurement by variables is used.
Lean (or JIT).

41. Residual
To do a capability study for a non-centered process.
=sqrt((p*(1-p)/n)
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

42. Define durability.
False - because each machine will have different natural tolerances.
A scatterplot.
10 for Hazardous without warning 1 for none
Mean time to replacement.

43. PFMEA
Shifts - Trends - Repeating patterns - Correlation with known events
To monitor a process when measurement by variables is used.
p-bar - the long-run percent defective.
Before production starts

44. What is poka yoke?
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
Before production starts
Mistake-proofing.
No -- only if the process is also capable.

45. What do you do when a process is out of control?
Mistake-proofing.
Look for the assignable cause of non-random variation.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Brand image.

46. FMEA
It looks to minimize the probability of a failure - or to minimize its effects
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
A tool that shows where there is waste in a process.
Fractional factorial designs (orthogonal arrays)

47. In a regression - what does the standard error of the estimate tell you?
Lower control limit.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Is the way in which the failure is manifested.
Shifts - Trends - Repeating patterns - Correlation with known events

48. Explain the difference between technical and functional service quality.
Look for the assignable cause of non-random variation.
Technical quality is the "what" of the service; functional quality is the "how."
Waste.
Lower skill requirements - faster - less chance for error.

49. What is Type II Error?
An assertion or conjecture concerning one or more populations
Method developed by Ishikawa to graphically display the causes of any given problem
= yij - y(bar)i --> value minus sum of that treatment (of row)
Concluding there has not been an effect/change when there has.

50. Affinity Diagrams
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Blame.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Studying firms with the best performance in a particular area.