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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?
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
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Rapid improvement process.
Consumer risk.

2. In the Service Quality Gap Model - what is Gap 3?
Upper control limit.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
The gap between specifications and how service is performed.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

3. PFMEA
Workers - machines - materials.
An assertion or conjecture concerning one or more populations
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Before production starts

4. In a regression - what does R-square tell you?
Lower control limit.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Not necessarily.
It's good -- but it's still out of control!

5. What is Kaizen?
= 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
Sort - Set in Order - Shine - Standardize - Sustain
Rapid improvement process.
Scrap - rework - retest - downtime - yield losses - disposition costs.

6. In the Service Quality Gap Model - what is Gap 1?
The gap between what management thinks customers want and what customers really want.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
99.73%
Fewer good units to sell - increased variable cost/unit.

7. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
The gap between what management thinks customers want and what customers really want.
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
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).

8. What is Jidoka?
The ability of a process to consistently meet customer specifications.
A random variable that summarizes the information from the sample(s).
Controlling quality at the source.
Used to create frequency distribution tally sheets

9. Taguchi's experimental designs are of this type.
Large enough to find two of the attribute - on average.
Fractional factorial designs (orthogonal arrays)
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).
A descending order-sorted bar chart with a cumulative percentage line.

10. Effect ranking (Severity of the Defect)
Outside.
Is the consequence of the failure.
10 for Hazardous without warning 1 for none
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

11. TWO-DIMENTIONAL SCATTER PLOT
Critical to quality.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

12. Statistical Hypothesis
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
Blame.
An assertion or conjecture concerning one or more populations
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

13. Defect check sheets
They move closer to the center line.
Different types of defects are listed (used for Pareto chart)
Conformance to specifications.
p-bar - the long-run percent defective.

14. Define serviceability.
Outside.
The gap between what customers expect and the service they receive.
Not necessarily.
Speed - courtesy - competence - and ease of repair.

15. In the Service Quality Gap Model - what is Gap 5?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The gap between what customers expect and the service they receive.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

16. What is the Deming Prize?
The secondary characteristics of a product; "bells and whistles."
95%
Consumer risk.
The Japanese national quality award.

17. What is the role of a black belt?
To manage the Six Sigma project.
What the value of the dependent variable is when the independent variable is zero.
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
99.73%

18. With Six Sigma capability - how many defects per million opportunities would you see?
To monitor a process when measurement by variables is used.
To monitor a process when measurement by attribute is used.
3.4 (assuming 1.5 sigma shift in the mean)
Not necessarily.

19. List Garvin's eight dimensions of product quality.
Supplier - input - process - output - customer.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
X-bar-bar
=sqrt(Σ(x-x-bar)^2)/(n-1))

20. What is the center line of a p-chart?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The gap between what management thinks customers want and the process specifications.
p-bar - the long-run percent defective.
Mean time to replacement.

21. What is Little's Law?
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.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Inventory = throughput x flow time.

22. Affinity Diagrams
100%
The ratio of outputs to inputs; 1-scrap.
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.

23. What are the four categories of costs in Juran's framework?
99.73%
Speed - courtesy - competence - and ease of repair.
Prevention - appraisal - internal failure - external failure.
The target number of standard deviations from the mean for specifications.

24. List two components of internal failure.
Prevention - appraisal - internal failure - external failure.
Different types of defects are listed (used for Pareto chart)
Pleasing to the senses.
Scrap - rework - retest - downtime - yield losses - disposition costs.

25. Disadvantages of DOE

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26. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Actual drawings - layouts - maps - etc which show where a defect occurs
Lean (or JIT).
What the value of the dependent variable is when the independent variable is zero.
Is the consequence of the failure.

27. What is a Gantt chart?
Waste.
Defects Per Million Opportunities
Shows the temporal flow of activities in a project network.
0.9^3 or 72.9%

28. What is DMADV?
Actual drawings - layouts - maps - etc which show where a defect occurs
50%
Lower skill requirements - faster - less chance for error.
Define - measure - analyze - design - verify.

29. What does a project prioritization matrix do?
The US national quality award.
Fitness for use.
Assigns scores to weighted criteria for each project under consideration.
Waste.

30. What is the 5S model?
A tool that shows where there is waste in a process.
The gap between what is promised and what is delivered.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

31. Creating a Run Chart
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The degree to which a product meets pre-established standards.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Observed variation in response is caused by the input

32. List two components of prevention cost.
p-bar - the long-run percent defective.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Lean (or JIT).

33. Presence of interaction effect
They move closer to the center line.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
The primary operating characteristics of a product.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

34. What percentage of a normal distribution lies above the mean?
50%
=sqrt(Σ(x-x-bar)^2)/(n-1))
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

35. Based on what principal can we use the normal distribution assumptions for SPC?
Sampling for SPC is done real time.
Central Limit Theorem
Fractional factorial designs (orthogonal arrays)
100%

36. FMEA
Different types of defects are listed (used for Pareto chart)
Causes that lead to a particular effect.
It looks to minimize the probability of a failure - or to minimize its effects
Studying firms with the best performance in a particular area.

37. What is the formula for standard deviation?
The gap between what management thinks customers want and what customers really want.
=sqrt(Σ(x-x-bar)^2)/(n-1))
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
Look for the assignable cause of non-random variation.

38. Why do you need two control charts for variables SPC?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Upper control limit.
Because the mean and standard deviation are independent of each other.
Technical quality is the "what" of the service; functional quality is the "how."

39. Definition of Interaction
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Variable.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

40. What is CTQ?
Critical to quality.
Causes that lead to a particular effect.
Brand image.
Attribute.

41. Name the structure associated with Quality Function Deployment.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
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 ratio of outputs to inputs; 1-scrap.
The House of Quality.

42. What quality guru emphasizes management as a system?
Concluding there has been an effect/change when there has not.
Deming.
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).
Pleasing to the senses.

43. What size should samples be for attribute SPC?
Large enough to find two of the attribute - on average.
Fractional factorial designs (orthogonal arrays)
Workers - machines - materials.
The ratio of outputs to inputs; 1-scrap.

44. What does the abbreviation UCL stand for?
Upper control limit.
False - because each machine will have different natural tolerances.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Observed variation in response is caused by the input

45. One factor at a time (OFAT)
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
95%
Organize ideas into meaningful categories by recognizing their underlying similarity
Hold all input variables constant except one. Observe the response as you vary the single input.

46. What is an affinity diagram?
A brainstorming tool that shows the connections between ideas.
To monitor a process when measurement by attribute is used.
Mean time to replacement.
To be a member of a Six Sigma project team.

47. How does Juran define quality?
Brand image.
Fitness for use.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
A brainstorming tool that shows the connections between ideas.

48. What is DPMO?
Rapid improvement process.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Defects Per Million Opportunities
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

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

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50. Define aesthetic quality.
Pleasing to the senses.
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:
Is the way in which the failure is manifested.
A diagram that shows the relationships between activities in a project network.