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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. Failure Mode
No -- the variation also has to be random and "expected."
Before production starts
Is the way in which the failure is manifested.
The gap between specifications and how service is performed.

2. Affinity Diagrams
A tool that shows where there is waste in a process.
The gap between what management thinks customers want and what customers really want.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Organize ideas into meaningful categories by recognizing their underlying similarity

3. What is a Gantt chart?
Shows the temporal flow of activities in a project network.
X-bar-bar
The gap between what management thinks customers want and what customers really want.
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

4. Definition of Interaction
To manage the Six Sigma project.
Fitness for use.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Pleasing to the senses.

5. When yields decrease - what are the two effects on contribution?
100%
Fewer good units to sell - increased variable cost/unit.
Defects Per Million Opportunities
Linearity - normality - homoscedasticity - independence.

6. What is the role of a green belt?
The secondary characteristics of a product; "bells and whistles."
To be a member of a Six Sigma project team.
Assigns scores to weighted criteria for each project under consideration.
Define - measure - analyze - design - verify.

7. What is Type 1 Error?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
No -- the variation also has to be random and "expected."
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Concluding there has been an effect/change when there has not.

8. Histogram by Hand
To obtain a certain desirable outcome from the process
Stratify a particular defect type according to logical criteria
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

9. What type of risk is associated with Type 1 Error?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Prevention and appraisal costs are balanced against internal and external failure.
Producer risk.
Attribute

10. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
50%
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

11. Uses of regression - Control
To monitor a process when measurement by attribute is used.
Kaoru Ishikawa.
To obtain a certain desirable outcome from the process
Because the mean and standard deviation are independent of each other.

12. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Lean (or JIT).
To be a member of a Six Sigma project team.
50%

13. What does the abbreviation UCL stand for?
Upper control limit.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
To monitor a process when measurement by attribute is used.

14. Detection Criteria Ranking
To monitor a process when measurement by variables is used.
A tool that shows where there is waste in a process.
10 if Almost impossible to detect
A tool that shows performance along key dimensions all at once.

15. Which quality guru developed the concept of loss to society?
p-bar - the long-run percent defective.
Taguchi
No -- the variation also has to be random and "expected."
95%

16. Process check sheets
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
A tool that shows the physical flows through a space.
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

17. Test for constant variance
Represents the behavior of a process
A descending order-sorted bar chart with a cumulative percentage line.
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).
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.

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 is the center line of a p-chart?
Brand image.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
p-bar - the long-run percent defective.
They move closer to the center line.

20. TWO-DIMENTIONAL SCATTER PLOT
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Lower skill requirements - faster - less chance for error.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Fitness for use.

21. What is an affinity diagram?
Initiated before or at design concept finalization
A brainstorming tool that shows the connections between ideas.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
A diagram that shows the relationships between activities in a project network.

22. Who first studied randomness in industrial processes
99.73%
Walter A. Shewhart
Controlling quality at the source.
The gap between what is promised and what is delivered.

23. What quality tool formally incorporates the voice of the customer?
=sqrt(Σ(x-x-bar)^2)/(n-1))
It's good -- but it's still out of control!
Assigns scores to weighted criteria for each project under consideration.
QFD

24. Pareto Analysis
The target number of standard deviations from the mean for specifications.
Supplier - input - process - output - customer.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Define - measure - analyze - improve - control.

25. Define serviceability.
Inventory = throughput x flow time.
Used to create frequency distribution tally sheets
Speed - courtesy - competence - and ease of repair.
Hold all input variables constant except one. Observe the response as you vary the single input.

26. Define performance quality.
The target number of standard deviations from the mean for specifications.
The primary operating characteristics of a product.
Consumer risk.
A diagram that shows the relationships between activities in a project network.

27. Define benchmarking.
Represents the behavior of a process
QFD
Studying firms with the best performance in a particular area.
To mentor/coach (and sometimes train) black belts.

28. Define conformance quality.
No -- only if the process is also capable.
Shows the temporal flow of activities in a project network.
Different types of defects are listed (used for Pareto chart)
The degree to which a product meets pre-established standards.

29. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
Taguchi
Attribute
QFD

30. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
No -- the variation also has to be random and "expected."
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Lower skill requirements - faster - less chance for error.

31. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
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
Actual drawings - layouts - maps - etc which show where a defect occurs
Mean time to replacement.
99.73%

32. Failure effect
Is the consequence of the failure.
The gap between what management thinks customers want and the process specifications.
Financial - customer - internal process - innovation and learning.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

33. What is poka yoke?
Hold all input variables constant except one. Observe the response as you vary the single input.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Shifts - Trends - Repeating patterns - Correlation with known events
Mistake-proofing.

34. Which type of SPC measurement is more precise - variable or attribute?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Variable.
F_alpha - df(tr) - df (error)
The primary operating characteristics of a product.

35. Explain the difference between technical and functional service quality.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
The secondary characteristics of a product; "bells and whistles."
Technical quality is the "what" of the service; functional quality is the "how."
Attribute.

36. What percentage of a normal distribution lies above the mean?
50%
Assigns scores to weighted criteria for each project under consideration.
Represents the behavior of a process
Is the consequence of the failure.

37. In a regression - what does R-square tell you?
QFD
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Lean is waste reduction - Six Sigma is variation reduction.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

38. What are the four categories of costs in Juran's framework?
The gap between what management thinks customers want and what customers really want.
Prevention - appraisal - internal failure - external failure.
=sqrt((p*(1-p)/n)
Upper control limit.

39. What type of risk is associated with Type II Error?
Define - measure - analyze - design - verify.
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:
The cycle time required to meet demand.
Consumer risk.

40. F value
Fishbone - cause-and-effect diagram.
Shows the temporal flow of activities in a project network.
Define - measure - analyze - improve - control.
F_alpha - df(tr) - df (error)

41. What are the 5 Ss?
Sort - Set in Order - Shine - Standardize - Sustain
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Because the mean and standard deviation are independent of each other.
Controlling quality at the source.

42. Defect location check sheets
Linearity - normality - homoscedasticity - independence.
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
Actual drawings - layouts - maps - etc which show where a defect occurs
To obtain a certain desirable outcome from the process

43. FMEA
The House of Quality.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Actual drawings - layouts - maps - etc which show where a defect occurs
It looks to minimize the probability of a failure - or to minimize its effects

44. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
Define - measure - analyze - improve - control.
A brainstorming tool that shows the connections between ideas.
Define - measure - analyze - design - verify.

45. Define takt time.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Rapid improvement process.
Through producer/consumer negotiation.
The cycle time required to meet demand.

46. To what does the Six in Six Sigma relate?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
3.4 (assuming 1.5 sigma shift in the mean)
The target number of standard deviations from the mean for specifications.
Attribute.

47. The Test Statistic (TS)
Observed variation in response is caused by the input
A random variable that summarizes the information from the sample(s).
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
To mentor/coach (and sometimes train) black belts.

48. In the Service Quality Gap Model - what is Gap 3?
Linearity - normality - homoscedasticity - independence.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
The gap between specifications and how service is performed.

49. PFMEA
Before production starts
Large enough to find two of the attribute - on average.
Conformance to specifications.
A time series plot.

50. A process is operating "in control." Does this mean the customer's requirements are met?
Linearity - normality - homoscedasticity - independence.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Assigns scores to weighted criteria for each project under consideration.
No -- only if the process is also capable.