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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. How are LQL and AQL determined in an acceptance sampling plan?
The gap between specifications and how service is performed.
Through producer/consumer negotiation.
=sqrt(Σ(x-x-bar)^2)/(n-1))
It looks to minimize the probability of a failure - or to minimize its effects

2. What is CTQ?
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).
Critical to quality.
10 for Hazardous without warning 1 for none
Defects Per Million Opportunities

3. A process is operating "in control." Does this mean the customer's requirements are met?
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
No -- only if the process is also capable.
The primary operating characteristics of a product.
Lean is waste reduction - Six Sigma is variation reduction.

4. In a Z table - what is Z?
The number of standard deviations some value is from the mean.
Sampling for SPC is done real time.
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
Mean time to replacement.

5. What quality guru emphasizes management as a system?
95%
Deming.
Shows the temporal flow of activities in a project network.
10 if Almost impossible to detect

6. In the Service Quality Gap Model - what is Gap 5?
The gap between what customers expect and the service they receive.
Walter A. Shewhart
Controlling quality at the source.
Deming.

7. Who is a process owner?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The manager in charge of a process being improved in a Six Sigma project.
Workers - machines - materials.
False - because each machine will have different natural tolerances.

8. Taguchi's experimental designs are of this type.
QFD
No -- the variation also has to be random and "expected."
Scrap - rework - retest - downtime - yield losses - disposition costs.
Fractional factorial designs (orthogonal arrays)

9. What does SIPOC stand for?
The degree to which a product meets pre-established standards.
Mean time to failure.
Concluding there has been an effect/change when there has not.
Supplier - input - process - output - customer.

10. Define serviceability.
Is the consequence of the failure.
Speed - courtesy - competence - and ease of repair.
To monitor a process when measurement by variables is used.
Is what induces the failure

11. What is a Gage R&R?
Hold all input variables constant except one. Observe the response as you vary the single input.
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).
The manager in charge of a process being improved in a Six Sigma project.
Failure Modes and Effects Analysis

12. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
The primary operating characteristics of a product.
Lean (or JIT).
Variable.
To manage the Six Sigma project.

13. Daniel Test
To mentor/coach (and sometimes train) black belts.
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:
Taguchi
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

14. What happens to control limits on an SPC chart when sample size is increased?
They move closer to the center line.
What the value of the dependent variable is when the independent variable is zero.
Conformance to specifications.
A tool that shows where there is waste in a process.

15. Effect ranking (Severity of the Defect)
Mean time to replacement.
Someone who is consistently against virtually everything.
False - because each machine will have different natural tolerances.
10 for Hazardous without warning 1 for none

16. Failure cause
3.4 (assuming 1.5 sigma shift in the mean)
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Is what induces the failure
F_alpha - df(tr) - df (error)

17. What does the abbreviation UCL stand for?
A brainstorming tool that shows the connections between ideas.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
The primary operating characteristics of a product.
Upper control limit.

18. Stratified defect check sheets
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 what customers really want.
Controlling quality at the source.
Stratify a particular defect type according to logical criteria

19. What is the Baldrige Award?
Large enough to find two of the attribute - on average.
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
The US national quality award.
The ratio of outputs to inputs; 1-scrap.

20. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
Blame.
100%
A descending order-sorted bar chart with a cumulative percentage line.
Not necessarily.

21. Why do you need two control charts for variables SPC?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Because the mean and standard deviation are independent of each other.
Concluding there has not been an effect/change when there has.
Walter A. Shewhart

22. Disadvantages of DOE

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23. In a regression - what does the p value of F tell you?
Supplier - input - process - output - customer.
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).
They move closer to the center line.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

24. Your production process meets customer specifications. Is your process in control?
To monitor a process when measurement by attribute is used.
Sort - Set in Order - Shine - Standardize - Sustain
Not necessarily.
=sqrt((p*(1-p)/n)

25. What is the formula for the standard deviation of a proportion?
A brainstorming tool that shows the connections between ideas.
Initiated before or at design concept finalization
Sort - Set in Order - Shine - Standardize - Sustain
=sqrt((p*(1-p)/n)

26. List two components of external failure.
Financial - customer - internal process - innovation and learning.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
It's good -- but it's still out of control!
Method developed by Ishikawa to graphically display the causes of any given problem

27. Process occurance ranking
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Is the consequence of the failure.
95%
Attribute.

28. What is process capability?
Attribute.
Concluding there has been an effect/change when there has not.
The ability of a process to consistently meet customer specifications.
10 for Hazardous without warning 1 for none

29. Residual
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Rapid improvement process.

30. What is a Pareto chart?
A descending order-sorted bar chart with a cumulative percentage line.
A tool that shows performance along key dimensions all at once.
The Japanese national quality award.
An assertion or conjecture concerning one or more populations

31. What does a project prioritization matrix do?
Conformance to specifications.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Studying firms with the best performance in a particular area.
Assigns scores to weighted criteria for each project under consideration.

32. What type of risk is associated with Type II Error?
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
What the value of the dependent variable is when the independent variable is zero.
Consumer risk.
Is the way in which the failure is manifested.

33. What is DMADV?
The gap between what customers expect and the service they receive.
Define - measure - analyze - design - verify.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Is the consequence of the failure.

34. What are the four categories of costs in Juran's framework?
Prevention - appraisal - internal failure - external failure.
To mentor/coach (and sometimes train) black belts.
Assigns scores to weighted criteria for each project under consideration.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

35. What is the role of a green belt?
To be a member of a Six Sigma project team.
Kaoru Ishikawa.
An assertion or conjecture concerning one or more populations
Fishbone - cause-and-effect diagram.

36. Risk Priority Number RPN
Assigns scores to weighted criteria for each project under consideration.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

37. Based on what principal can we use the normal distribution assumptions for SPC?
Mean time to replacement.
Fewer good units to sell - increased variable cost/unit.
Used to create frequency distribution tally sheets
Central Limit Theorem

38. What is the center line of an X-bar chart?
X-bar-bar
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Fitness for use.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

39. What size should samples be for attribute SPC?
Large enough to find two of the attribute - on average.
Used to create frequency distribution tally sheets
Sampling for SPC is done real time.
Mean time to replacement.

40. When yields decrease - what are the two effects on contribution?
= 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
Workers - machines - materials.
Fewer good units to sell - increased variable cost/unit.
Before production starts

41. What is the center line of a p-chart?
p-bar - the long-run percent defective.
Workers - machines - materials.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

42. What is a Gantt chart?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Shows the temporal flow of activities in a project network.
=sqrt((p*(1-p)/n)
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

43. Regression Analysis
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Controlling quality at the source.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
10 if Almost impossible to detect

44. Define performance quality.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
The primary operating characteristics of a product.
Waste.
Through producer/consumer negotiation.

45. DFMEA
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
A diagram that shows the relationships between activities in a project network.
Initiated before or at design concept finalization
Sort - Set in Order - Shine - Standardize - Sustain

46. Define yield.
The ratio of outputs to inputs; 1-scrap.
Assigns scores to weighted criteria for each project under consideration.
The degree to which a product meets pre-established standards.
Inventory = throughput x flow time.

47. Presence of interaction effect
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The gap between specifications and how service is performed.
Assigns scores to weighted criteria for each project under consideration.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

48. What are the four regression assumptions?
The gap between what is promised and what is delivered.
The ability of a process to consistently meet customer specifications.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Linearity - normality - homoscedasticity - independence.

49. Which type of SPC measurement is more precise - variable or attribute?
Lean is waste reduction - Six Sigma is variation reduction.
No -- the variation also has to be random and "expected."
100%
Variable.

50. What graphical tool is used to show the relationship between two numerical variables?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
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
A scatterplot.
Used to create frequency distribution tally sheets