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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. Which quality guru developed the concept of loss to society?
Taguchi
A random variable that summarizes the information from the sample(s).
Brand image.
X-bar-bar

2. Residual
The secondary characteristics of a product; "bells and whistles."
A scatterplot.
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.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

3. When is Cpk used?
The ability of a process to consistently meet customer specifications.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
To do a capability study for a non-centered process.
= yij - y(bar)i --> value minus sum of that treatment (of row)

4. What is the 5S model?
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.
To manage the Six Sigma project.
Lower control limit.

5. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
99.73%
Mean time to replacement.
Blame.
To manage the Six Sigma project.

6. What is the role of a master black belt?
To mentor/coach (and sometimes train) black belts.
Deming.
The gap between specifications and how service is performed.
Brand image.

7. Uses of regression
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
It's good -- but it's still out of control!
Define - measure - analyze - design - verify.
The ability of a process to consistently meet customer specifications.

8. What quality tool formally incorporates the voice of the customer?
Large enough to find two of the attribute - on average.
QFD
Outside.
Concluding there has not been an effect/change when there has.

9. DFMEA
Brand image.
The number of standard deviations some value is from the mean.
Initiated before or at design concept finalization
Taguchi

10. Cause and Effect Diagrams
Fewer good units to sell - increased variable cost/unit.
Scrap - rework - retest - downtime - yield losses - disposition costs.
To be a member of a Six Sigma project team.
Method developed by Ishikawa to graphically display the causes of any given problem

11. Who developed the fishbone diagram?
Kaoru Ishikawa.
Because the mean and standard deviation are independent of each other.
Used to create frequency distribution tally sheets
A diagram that shows the relationships between activities in a project network.

12. What happens to control limits on an SPC chart when sample size is increased?
Producer risk.
They move closer to the center line.
An assertion or conjecture concerning one or more populations
Defects Per Million Opportunities

13. Define product reliability.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Mean time to failure.
3.4 (assuming 1.5 sigma shift in the mean)
Rapid improvement process.

14. What are two other names for an Ishikawa diagram?
A descending order-sorted bar chart with a cumulative percentage line.
They move closer to the center line.
Fishbone - cause-and-effect diagram.
Is the way in which the failure is manifested.

15. Defect check sheets
Used to create frequency distribution tally sheets
99.73%
The gap between specifications and how service is performed.
Different types of defects are listed (used for Pareto chart)

16. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Lean (or JIT).
Initiated before or at design concept finalization
Assigns scores to weighted criteria for each project under consideration.
10 for Hazardous without warning 1 for none

17. Define takt time.
The cycle time required to meet demand.
Not necessarily.
100%
Through producer/consumer negotiation.

18. What is the center line of a p-chart?
p-bar - the long-run percent defective.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Outside.
To manage the Six Sigma project.

19. What type of risk is associated with Type II Error?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Consumer risk.
Producer risk.
Taguchi

20. List two components of internal failure.
The House of Quality.
Rapid improvement process.
Pleasing to the senses.
Scrap - rework - retest - downtime - yield losses - disposition costs.

21. What does Crosby say about benchmarking?
A scatterplot.
Different types of defects are listed (used for Pareto chart)
The primary operating characteristics of a product.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

22. What is Kaizen?
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 -- only if the process is also capable.
Rapid improvement process.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

23. In the Service Quality Gap Model - what is Gap 5?
To mentor/coach (and sometimes train) black belts.
The gap between what customers expect and the service they receive.
Technical quality is the "what" of the service; functional quality is the "how."
Fractional factorial designs (orthogonal arrays)

24. If a Cp shows that a process is not capable - should you calculate Cpk?
Represents the behavior of a process
No -- if it is not the same - it can only be worse!
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
To obtain a certain desirable outcome from the process

25. What does the abbreviation UCL stand for?
Sort - Set in Order - Shine - Standardize - Sustain
X-bar-bar
Fractional factorial designs (orthogonal arrays)
Upper control limit.

26. Define serviceability.
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:
Speed - courtesy - competence - and ease of repair.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Before production starts

27. What is a histogram?
They move closer to the center line.
The Japanese national quality award.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Scrap - rework - retest - downtime - yield losses - disposition costs.

28. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Sampling for SPC is done real time.
Controlling quality at the source.
Pleasing to the senses.

29. What is written on the "spines" of a fishbone diagram?
= yij - y(bar)i --> value minus sum of that treatment (of row)
Causes that lead to a particular effect.
Linearity - normality - homoscedasticity - independence.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

30. Define conformance quality.
Assigns scores to weighted criteria for each project under consideration.
Is the way in which the failure is manifested.
The degree to which a product meets pre-established standards.
Large enough to find two of the attribute - on average.

31. With Six Sigma capability - how many defects per million opportunities would you see?
To manage the Six Sigma project.
To obtain a certain desirable outcome from the process
3.4 (assuming 1.5 sigma shift in the mean)
Sort - Set in Order - Shine - Standardize - Sustain

32. Effect ranking (Severity of the Defect)
10 for Hazardous without warning 1 for none
A scatterplot.
Shows the temporal flow of activities in a project network.
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

33. When yields decrease - what are the two effects on contribution?
The gap between what management thinks customers want and what customers really want.
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).
Fewer good units to sell - increased variable cost/unit.
The manager in charge of a process being improved in a Six Sigma project.

34. Presence of interaction effect
Controlling quality at the source.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Stratify a particular defect type according to logical criteria

35. What are the 5 Ss?
Sort - Set in Order - Shine - Standardize - Sustain
Kaoru Ishikawa.
Outside.
Supplier - input - process - output - customer.

36. What is a Gage R&R?
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).
If the Response vs. Levels graph if the response lines are not parallel (crossing)
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
Conformance to specifications.

37. How does Juran define quality?
Fitness for use.
Large enough to find two of the attribute - on average.
Lower skill requirements - faster - less chance for error.
Is what induces the failure

38. Pareto Analysis
=sqrt((p*(1-p)/n)
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Fishbone - cause-and-effect diagram.

39. Define performance quality.
The primary operating characteristics of a product.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Mean time to failure.
Stratify a particular defect type according to logical criteria

40. What is an affinity diagram?
A brainstorming tool that shows the connections between ideas.
To be a member of a Six Sigma project team.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Kaoru Ishikawa.

41. Regression
To monitor a process when measurement by attribute is used.
Studying firms with the best performance in a particular area.
Represents the behavior of a process
Through producer/consumer negotiation.

42. Which type of SPC measurement is more precise - variable or attribute?
Variable.
Actual drawings - layouts - maps - etc which show where a defect occurs
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Brand image.

43. Process check sheets
Used to create frequency distribution tally sheets
Failure Modes and Effects Analysis
The gap between specifications and how service is performed.
Not necessarily.

44. Design of Experiments (DOE) approach
The gap between specifications and how service is performed.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The gap between what management thinks customers want and the process specifications.
Controlling quality at the source.

45. What is DMADV?
Defects Per Million Opportunities
The target number of standard deviations from the mean for specifications.
p-bar - the long-run percent defective.
Define - measure - analyze - design - verify.

46. In the Service Quality Gap Model - what is Gap 3?
The gap between what is promised and what is delivered.
What the value of the dependent variable is when the independent variable is zero.
Concluding there has not been an effect/change when there has.
The gap between specifications and how service is performed.

47. What is the role of a green belt?
It looks to minimize the probability of a failure - or to minimize its effects
Outside.
To be a member of a Six Sigma project team.
Shifts - Trends - Repeating patterns - Correlation with known events

48. 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.
Different types of defects are listed (used for Pareto chart)
Shows the temporal flow of activities in a project network.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

49. Define aesthetic quality.
Lean is waste reduction - Six Sigma is variation reduction.
50%
Pleasing to the senses.
A random variable that summarizes the information from the sample(s).

50. What does a project prioritization matrix do?
Concluding there has not been an effect/change when there has.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Can't tell without a Range chart.
Assigns scores to weighted criteria for each project under consideration.