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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. Design of Experiments (DOE) approach
Walter A. Shewhart
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
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The US national quality award.

2. What is DMADV?
Define - measure - analyze - design - verify.
p-bar - the long-run percent defective.
To mentor/coach (and sometimes train) black belts.
Mean time to failure.

3. Regression Analysis
Used to create frequency distribution tally sheets
Variable.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Mean time to replacement.

4. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Outside.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Lower skill requirements - faster - less chance for error.
Fishbone - cause-and-effect diagram.

5. With Six Sigma capability - how many defects per million opportunities would you see?
Attribute.
Pleasing to the senses.
3.4 (assuming 1.5 sigma shift in the mean)
Linearity - normality - homoscedasticity - independence.

6. Residual
Initiated before or at design concept finalization
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Is the consequence of the failure.

7. PFMEA
Before production starts
Deming.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The manager in charge of a process being improved in a Six Sigma project.

8. What is the role of a master black belt?
68%
To mentor/coach (and sometimes train) black belts.
50%
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

9. 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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10. A process is operating "in control." Does this mean the customer's requirements are met?
5%
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
A random variable that summarizes the information from the sample(s).
No -- only if the process is also capable.

11. DOE
False - because each machine will have different natural tolerances.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Deming.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

12. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Outside.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Variable.
Studying firms with the best performance in a particular area.

13. What type of risk is associated with Type 1 Error?
Producer risk.
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
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

14. What is a histogram?
No -- only if the process is also capable.
Central Limit Theorem
F_alpha - df(tr) - df (error)
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

15. Who developed the fishbone diagram?
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
The secondary characteristics of a product; "bells and whistles."
The Japanese national quality award.
Kaoru Ishikawa.

16. Who is a process owner?
Outside.
Assigns scores to weighted criteria for each project under consideration.
Kaoru Ishikawa.
The manager in charge of a process being improved in a Six Sigma project.

17. Complete this quality phrase: 'Fix the process - not the _____.'
To mentor/coach (and sometimes train) black belts.
Blame.
Define - measure - analyze - improve - control.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

18. In a Z table - what is Z?
A time series plot.
The number of standard deviations some value is from the mean.
Rapid improvement process.
The Japanese national quality award.

19. Define takt time.
The cycle time required to meet demand.
The House of Quality.
A brainstorming tool that shows the connections between ideas.
Attribute

20. Based on what principal can we use the normal distribution assumptions for SPC?
The target number of standard deviations from the mean for specifications.
Central Limit Theorem
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).
No -- only if the process is also capable.

21. Define performance quality.
A time series plot.
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
Kaoru Ishikawa.
The primary operating characteristics of a product.

22. What is a CAVE man?
Someone who is consistently against virtually everything.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
68%
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

23. What is Kaizen?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Rapid improvement process.
10 if Almost impossible to detect
p-bar - the long-run percent defective.

24. If you have calculated a Cpk - should you also calculate a Cp?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
=sqrt((p*(1-p)/n)
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

25. Define durability.
To do a capability study for a non-centered process.
Rapid improvement process.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Mean time to replacement.

26. Define yield.
Variable.
The ratio of outputs to inputs; 1-scrap.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Shifts - Trends - Repeating patterns - Correlation with known events

27. Presence of interaction effect
To monitor a process when measurement by attribute is used.
Define - measure - analyze - improve - control.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
If the Response vs. Levels graph if the response lines are not parallel (crossing)

28. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Observed variation in response is caused by the input
Workers - machines - materials.
The secondary characteristics of a product; "bells and whistles."
99.73%

29. In the Service Quality Gap Model - what is Gap 1?
The gap between what management thinks customers want and what customers really want.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Technical quality is the "what" of the service; functional quality is the "how."
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.

30. For what is a p-chart used?
It's good -- but it's still out of control!
To monitor a process when measurement by attribute is used.
A diagram that shows the relationships between activities in a project network.
A descending order-sorted bar chart with a cumulative percentage line.

31. What are the Five Dimensions of Service Quality?
Hold all input variables constant except one. Observe the response as you vary the single input.
They move closer to the center line.
The manager in charge of a process being improved in a Six Sigma project.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

32. In a regression - what does the standard error of the estimate tell you?
Organize ideas into meaningful categories by recognizing their underlying similarity
Kaoru Ishikawa.
99.73%
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

33. What does the abbreviation UCL stand for?
Fractional factorial designs (orthogonal arrays)
95%
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
Upper control limit.

34. List two components of external failure.
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
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Variable.
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:

35. 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.
No -- only if the process is also capable.
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
Lower skill requirements - faster - less chance for error.

36. What is a network diagram?
The House of Quality.
Organize ideas into meaningful categories by recognizing their underlying similarity
A diagram that shows the relationships between activities in a project network.
An assertion or conjecture concerning one or more populations

37. Define perceived quality (Garvin's framework).
Lower control limit.
3.4 (assuming 1.5 sigma shift in the mean)
Brand image.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

38. What are the 5 Ss?
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.
Sort - Set in Order - Shine - Standardize - Sustain
The gap between specifications and how service is performed.
Stratify a particular defect type according to logical criteria

39. Does it ever make sense to accept a job when a process is incapable?
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.
Before production starts
A random variable that summarizes the information from the sample(s).
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

40. What are the four regression assumptions?
10 if Almost impossible to detect
Define - measure - analyze - improve - control.
Linearity - normality - homoscedasticity - independence.
Consumer risk.

41. Residual(eij)
Through producer/consumer negotiation.
Outside.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

42. To what does the Six in Six Sigma relate?
A tool that shows the physical flows through a space.
Blame.
The target number of standard deviations from the mean for specifications.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

43. Defect location check sheets
Actual drawings - layouts - maps - etc which show where a defect occurs
The ability of a process to consistently meet customer specifications.
A tool that shows the physical flows through a space.
Producer risk.

44. What graphical tool is used to show the relationship between two numerical variables?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Conformance to specifications.
Look for the assignable cause of non-random variation.
A scatterplot.

45. In the Service Quality Gap Model - what is Gap 3?
Observed variation in response is caused by the input
Consumer risk.
The gap between specifications and how service is performed.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

46. 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.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
99.73%
The US national quality award.

47. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Large enough to find two of the attribute - on average.
Prevention and appraisal costs are balanced against internal and external failure.
Taguchi
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

48. Histogram by Hand
Hold all input variables constant except one. Observe the response as you vary the single input.
The Japanese national quality award.
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

49. What does Crosby say about benchmarking?
An assertion or conjecture concerning one or more populations
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Not necessarily.
Supplier - input - process - output - customer.

50. Manual Test for Nomality
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
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
95%