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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 inventory approach contributes to process quality by "lowering the river to find the rocks?"
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
Producer risk.
Lean (or JIT).
p-bar - the long-run percent defective.

2. Define yield.
The ratio of outputs to inputs; 1-scrap.
The US national quality award.
To do a capability study for a non-centered process.
Deming.

3. Does it ever make sense to accept a job when a process is incapable?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
=sqrt((p*(1-p)/n)
To monitor a process when measurement by variables is used.

4. F value
Mean time to replacement.
Is what induces the failure
F_alpha - df(tr) - df (error)
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

5. What quality tool formally incorporates the voice of the customer?
The US national quality award.
Can't tell without a Range chart.
QFD
Producer risk.

6. Simple Regression Analysis (one factor regression model)
A brainstorming tool that shows the connections between ideas.
Fewer good units to sell - increased variable cost/unit.
= 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
Initiated before or at design concept finalization

7. Define aesthetic quality.
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).
Define - measure - analyze - design - verify.
Mistake-proofing.
Pleasing to the senses.

8. Affinity Diagrams
The ability of a process to consistently meet customer specifications.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Mistake-proofing.
To do a capability study for a non-centered process.

9. What does a project prioritization matrix do?
Assigns scores to weighted criteria for each project under consideration.
The House of Quality.
Stratify a particular defect type according to logical criteria
They move closer to the center line.

10. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
QFD
Consumer risk.
Represents the behavior of a process
No -- the variation also has to be random and "expected."

11. Risk Priority Number RPN
=sqrt(Σ(x-x-bar)^2)/(n-1))
68%
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Upper control limit.

12. Which quality guru developed the concept of loss to society?
Taguchi
No -- the variation also has to be random and "expected."
Walter A. Shewhart
10 if Almost impossible to detect

13. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Fractional factorial designs (orthogonal arrays)
68%
Lower skill requirements - faster - less chance for error.
Prevention - appraisal - internal failure - external failure.

14. In a regression - what does the coefficient of the intercept tell you
To do a capability study for a non-centered process.
95%
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
What the value of the dependent variable is when the independent variable is zero.

15. The Test Statistic (TS)
Variable.
A random variable that summarizes the information from the sample(s).
The gap between what is promised and what is delivered.
A descending order-sorted bar chart with a cumulative percentage line.

16. What is a dashboard?
Is what induces the failure
The ratio of outputs to inputs; 1-scrap.
A tool that shows performance along key dimensions all at once.
To do a capability study for a non-centered process.

17. Based on what principal can we use the normal distribution assumptions for SPC?
Attribute.
Define - measure - analyze - improve - control.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Central Limit Theorem

18. How does Juran define quality?
Sampling for SPC is done real time.
A descending order-sorted bar chart with a cumulative percentage line.
Fitness for use.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

19. When is Cpk used?
99.73%
p-bar - the long-run percent defective.
To do a capability study for a non-centered process.
No -- the variation also has to be random and "expected."

20. When yields decrease - what are the two effects on contribution?
The gap between what management thinks customers want and the process specifications.
Mean time to replacement.
Fewer good units to sell - increased variable cost/unit.
Controlling quality at the source.

21. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
False - because each machine will have different natural tolerances.
Prevention - appraisal - internal failure - external failure.
100%
10 if Almost impossible to detect

22. Defect check sheets
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Actual drawings - layouts - maps - etc which show where a defect occurs
QFD
Different types of defects are listed (used for Pareto chart)

23. Which type of SPC measurement is more precise - variable or attribute?
It looks to minimize the probability of a failure - or to minimize its effects
Variable.
0.9^3 or 72.9%
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

24. What is the Deming Prize?
Through producer/consumer negotiation.
A brainstorming tool that shows the connections between ideas.
A tool that shows performance along key dimensions all at once.
The Japanese national quality award.

25. Design of Experiments (DOE) approach
Producer risk.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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.
The gap between what is promised and what is delivered.

26. FMEA
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Sampling for SPC is done real time.
Observed variation in response is caused by the input
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

27. For what is a p-chart used?
Causes that lead to a particular effect.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Sort - Set in Order - Shine - Standardize - Sustain
To monitor a process when measurement by attribute is used.

28. What do you do when a process is out of control?
To do a capability study for a non-centered process.
Look for the assignable cause of non-random variation.
The gap between what management thinks customers want and what customers really want.
Lower skill requirements - faster - less chance for error.

29. What is the difference between the way sampling is done for SPC and for acceptance sampling?
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
Sampling for SPC is done real time.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Variable.

30. In the Service Quality Gap Model - what is Gap 4?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Speed - courtesy - competence - and ease of repair.
Studying firms with the best performance in a particular area.
The gap between what is promised and what is delivered.

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.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The gap between what customers expect and the service they receive.
5%

32. Residual
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
Fewer good units to sell - increased variable cost/unit.
The gap between what management thinks customers want and what customers really want.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

33. Define features.
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).
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
The secondary characteristics of a product; "bells and whistles."
Deming.

34. List Garvin's eight dimensions of product quality.
The cycle time required to meet demand.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
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
=sqrt((p*(1-p)/n)

35. Your production process meets customer specifications. Is your process in control?
Not necessarily.
Represents the behavior of a process
An assertion or conjecture concerning one or more populations
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).

36. What percentage of a normal distribution lies above the mean?
Linearity - normality - homoscedasticity - independence.
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.
50%
The target number of standard deviations from the mean for specifications.

37. What is Type 1 Error?
Concluding there has been an effect/change when there has not.
Blame.
A tool that shows where there is waste in a process.
Conformance to specifications.

38. Define perceived quality (Garvin's framework).
Assigns scores to weighted criteria for each project under consideration.
Brand image.
A scatterplot.
Sampling for SPC is done real time.

39. What is Type II Error?
Concluding there has not been an effect/change when there has.
The degree to which a product meets pre-established standards.
10 for Hazardous without warning 1 for none
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

40. What is muda
An assertion or conjecture concerning one or more populations
Waste.
It's good -- but it's still out of control!
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

41. List two appraisal costs.
Speed - courtesy - competence - and ease of repair.
Hold all input variables constant except one. Observe the response as you vary the single input.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Rapid improvement process.

42. If you have calculated a Cpk - should you also calculate a Cp?
Shifts - Trends - Repeating patterns - Correlation with known events
50%
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Someone who is consistently against virtually everything.

43. What is DMADV?
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:
A time series plot.
Define - measure - analyze - design - verify.
To monitor a process when measurement by attribute is used.

44. A process is operating "in control." Does this mean the customer's requirements are met?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
To do a capability study for a non-centered process.
No -- only if the process is also capable.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

45. Name the structure associated with Quality Function Deployment.
p-bar - the long-run percent defective.
Sampling for SPC is done real time.
The House of Quality.
5%

46. Creating a Run Chart
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Stratify a particular defect type according to logical criteria
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Someone who is consistently against virtually everything.

47. What are two other names for an Ishikawa diagram?
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
Fishbone - cause-and-effect diagram.
Used to create frequency distribution tally sheets
Fitness for use.

48. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
The target number of standard deviations from the mean for specifications.
5%
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Conformance to specifications.

49. Affinity Diagrams
Organize ideas into meaningful categories by recognizing their underlying similarity
Speed - courtesy - competence - and ease of repair.
Brand image.
The primary operating characteristics of a product.

50. In a Z table - what is Z?
Is the way in which the failure is manifested.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The number of standard deviations some value is from the mean.
95%