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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. If you can only collect categorical data - what type of SPC charting can you do?
Lean (or JIT).
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Attribute.
X-bar-bar

2. Regression
Represents the behavior of a process
To monitor a process when measurement by variables is used.
False - because each machine will have different natural tolerances.
Prevention - appraisal - internal failure - external failure.

3. Failure cause
Is what induces the failure
The gap between what customers expect and the service they receive.
3.4 (assuming 1.5 sigma shift in the mean)
To mentor/coach (and sometimes train) black belts.

4. Explain the difference between technical and functional service quality.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Technical quality is the "what" of the service; functional quality is the "how."
The manager in charge of a process being improved in a Six Sigma project.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

5. Failure effect
Supplier - input - process - output - customer.
Before production starts
Define - measure - analyze - improve - control.
Is the consequence of the failure.

6. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
The gap between what customers expect and the service they receive.
The gap between what management thinks customers want and the process specifications.

7. What is a spaghetti diagram?
A time series plot.
What the value of the dependent variable is when the independent variable is zero.
A tool that shows the physical flows through a space.
p-bar - the long-run percent defective.

8. In the Service Quality Gap Model - what is Gap 5?
The ability of a process to consistently meet customer specifications.
Conformance to specifications.
The gap between what customers expect and the service they receive.
They move closer to the center line.

9. Define benchmarking.
10 for Hazardous without warning 1 for none
Studying firms with the best performance in a particular area.
Stratify a particular defect type according to logical criteria
Attribute.

10. Failure Mode
Speed - courtesy - competence - and ease of repair.
Is the way in which the failure is manifested.
3.4 (assuming 1.5 sigma shift in the mean)
A tool that shows the physical flows through a space.

11. What does the abbreviation LCL stand for?
Lower control limit.
Lean is waste reduction - Six Sigma is variation reduction.
The ratio of outputs to inputs; 1-scrap.
Blame.

12. What is a Gage R&R?
Consumer risk.
Used to create frequency distribution tally sheets
Method developed by Ishikawa to graphically display the causes of any given problem
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).

13. In a regression - what does R-square tell you?
F_alpha - df(tr) - df (error)
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 amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Define - measure - analyze - improve - control.

14. With Six Sigma capability - how many defects per million opportunities would you see?
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
Shifts - Trends - Repeating patterns - Correlation with known events
=sqrt((p*(1-p)/n)
3.4 (assuming 1.5 sigma shift in the mean)

15. What is a run chart?
To monitor a process when measurement by variables is used.
A time series plot.
Studying firms with the best performance in a particular area.
The gap between specifications and how service is performed.

16. What does DMAIC stand for?
A descending order-sorted bar chart with a cumulative percentage line.
The House of Quality.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Define - measure - analyze - improve - control.

17. Risk Priority Number RPN
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

18. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
Can't tell without a Range chart.
Define - measure - analyze - improve - control.
Linearity - normality - homoscedasticity - independence.

19. What is muda
F_alpha - df(tr) - df (error)
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Waste.
Speed - courtesy - competence - and ease of repair.

20. What size should samples be for attribute SPC?
Mistake-proofing.
Large enough to find two of the attribute - on average.
What the value of the dependent variable is when the independent variable is zero.
QFD

21. What is a network 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
68%
A diagram that shows the relationships between activities in a project network.
Lean (or JIT).

22. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Lean is waste reduction - Six Sigma is variation reduction.
Because the mean and standard deviation are independent of each other.
Lean (or JIT).
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

23. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
To mentor/coach (and sometimes train) black belts.
5%
Walter A. Shewhart
99.73%

24. What is Type 1 Error?
A tool that shows where there is waste in a process.
68%
Concluding there has been an effect/change when there has not.
The cycle time required to meet demand.

25. In a Z table - what is Z?
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
Controlling quality at the source.
The number of standard deviations some value is from the mean.
Because the mean and standard deviation are independent of each other.

26. What does the abbreviation UCL stand for?
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.
The gap between specifications and how service is performed.
Upper control limit.

27. In a regression - what does the standard error of the estimate tell you?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Defects Per Million Opportunities
Actual drawings - layouts - maps - etc which show where a defect occurs

28. Pareto Analysis
=sqrt((p*(1-p)/n)
Brand image.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Concluding there has not been an effect/change when there has.

29. Define yield.
F_alpha - df(tr) - df (error)
A diagram that shows the relationships between activities in a project network.
The ratio of outputs to inputs; 1-scrap.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

30. A process is operating "in control." Does this mean the customer's requirements are met?
No -- only if the process is also capable.
Scrap - rework - retest - downtime - yield losses - disposition costs.
The gap between what management thinks customers want and the process specifications.
A random variable that summarizes the information from the sample(s).

31. If a three-stage process has 90% yields at each stage - what is the overall yield?
Pleasing to the senses.
0.9^3 or 72.9%
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
Look for the assignable cause of non-random variation.

32. Non-random patterns (Run Charts)
p-bar - the long-run percent defective.
Concluding there has been an effect/change when there has not.
Shifts - Trends - Repeating patterns - Correlation with known events
Taguchi

33. What is the Baldrige Award?
Waste.
The US national quality award.
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
Reliability - Assurance - Responsiveness - Tangibles - Empathy

34. The Test Statistic (TS)
p-bar - the long-run percent defective.
Before production starts
It's good -- but it's still out of control!
A random variable that summarizes the information from the sample(s).

35. What is DMADV?
Define - measure - analyze - design - verify.
X-bar-bar
The US national quality award.
Concluding there has not been an effect/change when there has.

36. Daniel Test
68%
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:
They move closer to the center line.
The cycle time required to meet demand.

37. What percentage of a normal distribution lies above the mean?
50%
Workers - machines - materials.
The degree to which a product meets pre-established standards.
Look for the assignable cause of non-random variation.

38. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
F_alpha - df(tr) - df (error)
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Different types of defects are listed (used for Pareto chart)
68%

39. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Variable.
Because the mean and standard deviation are independent of each other.
The manager in charge of a process being improved in a Six Sigma project.
Concluding there has not been an effect/change when there has.

40. What are the four categories of costs in Juran's framework?
A tool that shows performance along key dimensions all at once.
Prevention - appraisal - internal failure - external failure.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

41. What is the center line of a p-chart?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
p-bar - the long-run percent defective.
Represents the behavior of a process
Mean time to failure.

42. What is CTQ?
Critical to quality.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
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).
It looks to minimize the probability of a failure - or to minimize its effects

43. When is Cpk used?
Kaoru Ishikawa.
Fewer good units to sell - increased variable cost/unit.
Failure Modes and Effects Analysis
To do a capability study for a non-centered process.

44. Complete this quality phrase: 'Fix the process - not the _____.'
Shifts - Trends - Repeating patterns - Correlation with known events
Blame.
5%
They move closer to the center line.

45. Test for Independence
They move closer to the center line.
Large enough to find two of the attribute - on average.
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
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

46. Who first studied randomness in industrial processes
Walter A. Shewhart
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
They move closer to the center line.
Variable.

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

48. Who developed the fishbone diagram?
Failure Modes and Effects Analysis
Kaoru Ishikawa.
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).
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

49. List two components of external failure.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Through producer/consumer negotiation.
Rapid improvement process.
95%

50. Affinity Diagrams
A tool that shows the physical flows through a space.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
To mentor/coach (and sometimes train) black belts.
Lower control limit.