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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 is an affinity diagram?
Assigns scores to weighted criteria for each project under consideration.
A brainstorming tool that shows the connections between ideas.
The degree to which a product meets pre-established standards.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

2. What quality tool formally incorporates the voice of the customer?
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
QFD
95%
Shifts - Trends - Repeating patterns - Correlation with known events

3. What are the Five Dimensions of Service Quality?
99.73%
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Upper control limit.
Concluding there has been an effect/change when there has not.

4. Advantages of DOE
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Observed variation in response is caused by the input
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
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

5. Non-random patterns (Run Charts)
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Shifts - Trends - Repeating patterns - Correlation with known events
Concluding there has not been an effect/change when there has.

6. What is a network diagram?
Mistake-proofing.
A diagram that shows the relationships between activities in a project network.
Variable.
To do a capability study for a non-centered process.

7. FMEA
99.73%
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
A time series plot.
It looks to minimize the probability of a failure - or to minimize its effects

8. What size should samples be for attribute SPC?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Fewer good units to sell - increased variable cost/unit.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Large enough to find two of the attribute - on average.

9. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Prevention and appraisal costs are balanced against internal and external failure.
Hold all input variables constant except one. Observe the response as you vary the single input.
Deming.
Lean (or JIT).

10. Define takt time.
The cycle time required to meet demand.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Consumer risk.
What the value of the dependent variable is when the independent variable is zero.

11. Define aesthetic quality.
Defects Per Million Opportunities
Organize ideas into meaningful categories by recognizing their underlying similarity
Pleasing to the senses.
Variable.

12. 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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13. Who first studied randomness in industrial processes
To obtain a certain desirable outcome from the process
Blame.
Speed - courtesy - competence - and ease of repair.
Walter A. Shewhart

14. Manual Test for Nomality
Lean is waste reduction - Six Sigma is variation reduction.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Critical to quality.
Shows the temporal flow of activities in a project network.

15. 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
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
It looks to minimize the probability of a failure - or to minimize its effects

16. Who developed the fishbone diagram?
Kaoru Ishikawa.
To obtain a certain desirable outcome from the process
Walter A. Shewhart
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

17. What is Jidoka?
Controlling quality at the source.
The primary operating characteristics of a product.
QFD
Initiated before or at design concept finalization

18. If a Cp shows that a process is not capable - should you calculate Cpk?
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
No -- if it is not the same - it can only be worse!
= yij - y(bar)i --> value minus sum of that treatment (of row)
A tool that shows where there is waste in a process.

19. What are the three main categories of assignable cause?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Workers - machines - materials.
Concluding there has been an effect/change when there has not.
A descending order-sorted bar chart with a cumulative percentage line.

20. Affinity Diagrams
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Is what induces the failure
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

21. Process check sheets
The Japanese national quality award.
Fitness for use.
Used to create frequency distribution tally sheets
Actual drawings - layouts - maps - etc which show where a defect occurs

22. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
The US national quality award.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The gap between specifications and how service is performed.

23. What is Type 1 Error?
The gap between what is promised and what is delivered.
Concluding there has been an effect/change when there has not.
The degree to which a product meets pre-established standards.
A scatterplot.

24. Test for Independence
= yij - y(bar)i --> value minus sum of that treatment (of row)
Rapid improvement process.
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
Not necessarily.

25. List two components of prevention cost.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Studying firms with the best performance in a particular area.
99.73%
Variable.

26. Design of Experiments (DOE) approach
Fitness for use.
To monitor a process when measurement by variables is used.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

27. What is a Gage R&R?
Observed variation in response is caused by the input
5%
Shows the temporal flow of activities in a project network.
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).

28. FMEA
Sampling for SPC is done real time.
Taguchi
A time series plot.
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

29. In a regression - what does the standard error of the estimate tell you?
Represents the behavior of a process
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Define - measure - analyze - improve - control.
Variable.

30. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Different types of defects are listed (used for Pareto chart)
Mistake-proofing.
Attribute
A diagram that shows the relationships between activities in a project network.

31. 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.
Hold all input variables constant except one. Observe the response as you vary the single input.
Technical quality is the "what" of the service; functional quality is the "how."
Shows the temporal flow of activities in a project network.

32. In a Z table - what is Z?
The number of standard deviations some value is from the mean.
Producer risk.
A brainstorming tool that shows the connections between ideas.
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).

33. Failure cause
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
A random variable that summarizes the information from the sample(s).
Is what induces the failure
To monitor a process when measurement by variables is used.

34. One factor at a time (OFAT)
Variable.
Hold all input variables constant except one. Observe the response as you vary the single input.
95%
A time series plot.

35. Define perceived quality (Garvin's framework).
Producer risk.
Because the mean and standard deviation are independent of each other.
Brand image.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

36. What is a spaghetti diagram?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
No -- if it is not the same - it can only be worse!
A tool that shows the physical flows through a space.

37. What type of risk is associated with Type 1 Error?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Is the way in which the failure is manifested.
X-bar-bar
Producer risk.

38. When yields decrease - what are the two effects on contribution?
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
Fewer good units to sell - increased variable cost/unit.
Brand image.
Producer risk.

39. Histogram by Hand
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
Sort - Set in Order - Shine - Standardize - Sustain
Fitness for use.
The secondary characteristics of a product; "bells and whistles."

40. With Six Sigma capability - how many defects per million opportunities would you see?
3.4 (assuming 1.5 sigma shift in the mean)
F_alpha - df(tr) - df (error)
Prevention and appraisal costs are balanced against internal and external failure.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

41. What is the center line of a p-chart?
The gap between what management thinks customers want and what customers really want.
=sqrt(Σ(x-x-bar)^2)/(n-1))
p-bar - the long-run percent defective.
Method developed by Ishikawa to graphically display the causes of any given problem

42. List two components of internal failure.
Mean time to replacement.
To monitor a process when measurement by variables is used.
Scrap - rework - retest - downtime - yield losses - disposition costs.
A tool that shows the physical flows through a space.

43. Define performance quality.
Assigns scores to weighted criteria for each project under consideration.
False - because each machine will have different natural tolerances.
The primary operating characteristics of a product.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

44. Defect location check sheets
95%
A tool that shows the physical flows through a space.
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).
Actual drawings - layouts - maps - etc which show where a defect occurs

45. What is DPMO?
Shifts - Trends - Repeating patterns - Correlation with known events
Taguchi
The ratio of outputs to inputs; 1-scrap.
Defects Per Million Opportunities

46. Based on what principal can we use the normal distribution assumptions for SPC?
Brand image.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Central Limit Theorem
=sqrt((p*(1-p)/n)

47. Test for constant variance
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.
Because the mean and standard deviation are independent of each other.
A time series plot.
False - because each machine will have different natural tolerances.

48. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Prevention and appraisal costs are balanced against internal and external failure.
A time series plot.
Deming.
To obtain a certain desirable outcome from the process

49. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Upper control limit.
Scrap - rework - retest - downtime - yield losses - disposition costs.
5%
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

50. Define serviceability.
Is the consequence of the failure.
Define - measure - analyze - improve - control.
The US national quality award.
Speed - courtesy - competence - and ease of repair.