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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 type of risk is associated with Type II Error?
Mistake-proofing.
Consumer risk.
5%
The gap between specifications and how service is performed.

2. What are the four perspectives of the Balanced Scorecard?
Failure Modes and Effects Analysis
Central Limit Theorem
Prevention and appraisal costs are balanced against internal and external failure.
Financial - customer - internal process - innovation and learning.

3. Taguchi's experimental designs are of this type.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Before production starts
Fractional factorial designs (orthogonal arrays)
The Japanese national quality award.

4. What is DMADV?
Lean is waste reduction - Six Sigma is variation reduction.
Can't tell without a Range chart.
Define - measure - analyze - design - verify.
Central Limit Theorem

5. How are LQL and AQL determined in an acceptance sampling plan?
The Japanese national quality award.
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.
Through producer/consumer negotiation.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

6. Test for constant variance
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
= yij - y(bar)i --> value minus sum of that treatment (of row)
The gap between what management thinks customers want and the process specifications.
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.

7. If a three-stage process has 90% yields at each stage - what is the overall yield?
Lower skill requirements - faster - less chance for error.
0.9^3 or 72.9%
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).
Studying firms with the best performance in a particular area.

8. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Outside.
A brainstorming tool that shows the connections between ideas.
No -- if it is not the same - it can only be worse!
The degree to which a product meets pre-established standards.

9. What does the abbreviation UCL stand for?
Upper control limit.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Blame.
Mean time to replacement.

10. List two appraisal costs.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Upper control limit.
Attribute

11. Failure effect
Define - measure - analyze - improve - control.
Is the consequence of the failure.
Workers - machines - materials.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

12. FMEA
They move closer to the center line.
It looks to minimize the probability of a failure - or to minimize its effects
A diagram that shows the relationships between activities in a project network.
A time series plot.

13. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
= 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 -- only if the process is also capable.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

14. What does a project prioritization matrix do?
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).
Assigns scores to weighted criteria for each project under consideration.
Represents the behavior of a process
The Japanese national quality award.

15. Creating a Run Chart
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.
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
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

16. Define takt time.
Lean (or JIT).
Critical to quality.
The cycle time required to meet demand.
Is the way in which the failure is manifested.

17. Define benchmarking.
The Japanese national quality award.
Studying firms with the best performance in a particular area.
To be a member of a Six Sigma project team.
Producer risk.

18. Manual Test for Nomality
Look for the assignable cause of non-random variation.
Actual drawings - layouts - maps - etc which show where a defect occurs
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
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

19. What is the 5S model?
Organize ideas into meaningful categories by recognizing their underlying similarity
The House of Quality.
A diagram that shows the relationships between activities in a project network.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

20. What is the difference between the way sampling is done for SPC and for acceptance sampling?
An assertion or conjecture concerning one or more populations
Sampling for SPC is done real time.
A random variable that summarizes the information from the sample(s).
Workers - machines - materials.

21. Define features.
Defects Per Million Opportunities
Walter A. Shewhart
The secondary characteristics of a product; "bells and whistles."
Observed variation in response is caused by the input

22. Effect ranking (Severity of the Defect)
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).
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
10 for Hazardous without warning 1 for none
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

23. Regression
Concluding there has not been an effect/change when there has.
Represents the behavior of a process
Not necessarily.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

24. Process check sheets
Large enough to find two of the attribute - on average.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Used to create frequency distribution tally sheets
The US national quality award.

25. FMEA
3.4 (assuming 1.5 sigma shift in the mean)
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
A tool that shows the physical flows through a space.
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

26. Affinity Diagrams
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
What the value of the dependent variable is when the independent variable is zero.
Organize ideas into meaningful categories by recognizing their underlying similarity
Deming.

27. Cause and Effect Diagrams
The House of Quality.
Method developed by Ishikawa to graphically display the causes of any given problem
A tool that shows the physical flows through a space.
Is the consequence of the failure.

28. How does Juran define quality?
The cycle time required to meet demand.
Attribute
Fitness for use.
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).

29. What is Type 1 Error?
Controlling quality at the source.
Concluding there has been an effect/change when there has not.
A scatterplot.
Sort - Set in Order - Shine - Standardize - Sustain

30. What is the role of a black belt?
Lean is waste reduction - Six Sigma is variation reduction.
Assigns scores to weighted criteria for each project under consideration.
A descending order-sorted bar chart with a cumulative percentage line.
To manage the Six Sigma project.

31. Which type of SPC measurement is more precise - variable or attribute?
Upper control limit.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Variable.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

32. Residual(eij)
A diagram that shows the relationships between activities in a project network.
Hold all input variables constant except one. Observe the response as you vary the single input.
= yij - y(bar)i --> value minus sum of that treatment (of row)
The ratio of outputs to inputs; 1-scrap.

33. What is Jidoka?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Controlling quality at the source.
Outside.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

34. What is the role of a green belt?
Supplier - input - process - output - customer.
Because the mean and standard deviation are independent of each other.
Observed variation in response is caused by the input
To be a member of a Six Sigma project team.

35. What is a CAVE man?
=sqrt((p*(1-p)/n)
Someone who is consistently against virtually everything.
Lower skill requirements - faster - less chance for error.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

36. What are the four regression assumptions?
The House of Quality.
Linearity - normality - homoscedasticity - independence.
Scrap - rework - retest - downtime - yield losses - disposition costs.
The number of standard deviations some value is from the mean.

37. Define conformance quality.
To obtain a certain desirable outcome from the process
F_alpha - df(tr) - df (error)
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 degree to which a product meets pre-established standards.

38. Statistical Hypothesis
10 if Almost impossible to detect
An assertion or conjecture concerning one or more populations
A tool that shows performance along key dimensions all at once.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

39. What is the role of a master black belt?
They move closer to the center line.
To mentor/coach (and sometimes train) black belts.
Concluding there has been an effect/change when there has not.
Kaoru Ishikawa.

40. What is a Pareto chart?
10 for Hazardous without warning 1 for none
Causes that lead to a particular effect.
Define - measure - analyze - design - verify.
A descending order-sorted bar chart with a cumulative percentage line.

41. In the Service Quality Gap Model - what is Gap 5?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Different types of defects are listed (used for Pareto chart)
Reliability - Assurance - Responsiveness - Tangibles - Empathy
The gap between what customers expect and the service they receive.

42. Simple Regression Analysis (one factor regression model)
Blame.
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
= 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

43. Process occurance ranking
Mistake-proofing.
Variable.
Blame.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

44. 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?
68%
False - because each machine will have different natural tolerances.
3.4 (assuming 1.5 sigma shift in the mean)
Actual drawings - layouts - maps - etc which show where a defect occurs

45. 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.
To be a member of a Six Sigma project team.
Brand image.
To manage the Six Sigma project.

46. What is the difference between Lean and Six Sigma?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
95%
Lean is waste reduction - Six Sigma is variation reduction.
Is what induces the failure

47. If a Cp shows that a process is not capable - should you calculate Cpk?
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
95%
No -- if it is not the same - it can only be worse!
A descending order-sorted bar chart with a cumulative percentage line.

48. In the Service Quality Gap Model - what is Gap 3?
The gap between specifications and how service is performed.
Conformance to specifications.
Pleasing to the senses.
Concluding there has been an effect/change when there has not.

49. If you have calculated a Cpk - should you also calculate a Cp?
Sampling for SPC is done real time.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Can't tell without a Range chart.
A brainstorming tool that shows the connections between ideas.

50. What does Crosby say about benchmarking?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
False - because each machine will have different natural tolerances.
A tool that shows the physical flows through a space.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.