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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. In a regression - what does the standard error of the estimate tell you?
Sort - Set in Order - Shine - Standardize - Sustain
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Large enough to find two of the attribute - on average.

2. What is the role of a master black belt?
To mentor/coach (and sometimes train) black belts.
Concluding there has been an effect/change when there has not.
95%
p-bar - the long-run percent defective.

3. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Producer risk.
5%
The cycle time required to meet demand.
Not necessarily.

4. Creating a Run Chart
Financial - customer - internal process - innovation and learning.
95%
The number of standard deviations some value is from the mean.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

5. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Defects Per Million Opportunities
Lean is waste reduction - Six Sigma is variation reduction.
Prevention and appraisal costs are balanced against internal and external failure.
= 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

6. Define aesthetic quality.
Pleasing to the senses.
Before production starts
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Waste.

7. Defect location check sheets
Stratify a particular defect type according to logical criteria
Actual drawings - layouts - maps - etc which show where a defect occurs
100%
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

8. What is a Gantt chart?
= 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
The gap between what is promised and what is delivered.
Shows the temporal flow of activities in a project network.
The primary operating characteristics of a product.

9. Define yield.
Outside.
The gap between what customers expect and the service they receive.
Consumer risk.
The ratio of outputs to inputs; 1-scrap.

10. Your production process meets customer specifications. Is your process in control?
Define - measure - analyze - improve - control.
Not necessarily.
100%
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

11. What do you do when a process is out of control?
Look for the assignable cause of non-random variation.
The gap between what management thinks customers want and the process specifications.
Supplier - input - process - output - customer.
Causes that lead to a particular effect.

12. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Hold all input variables constant except one. Observe the response as you vary the single input.
A time series plot.

13. What are the four regression assumptions?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Taguchi
Brand image.
Linearity - normality - homoscedasticity - independence.

14. What is a dashboard?
No -- if it is not the same - it can only be worse!
Walter A. Shewhart
A tool that shows performance along key dimensions all at once.
Waste.

15. How does Juran define quality?
=sqrt((p*(1-p)/n)
A time series plot.
Fitness for use.
Actual drawings - layouts - maps - etc which show where a defect occurs

16. Manual Test for Nomality
A brainstorming tool that shows the connections between ideas.
Controlling quality at the source.
Concluding there has been an effect/change when there has not.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

17. What is the Deming Prize?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
The Japanese national quality award.
No -- only if the process is also capable.
Actual drawings - layouts - maps - etc which show where a defect occurs

18. In a regression - what does R-square tell you?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
No -- if it is not the same - it can only be worse!
F_alpha - df(tr) - df (error)
The primary operating characteristics of a product.

19. Define performance quality.
Failure Modes and Effects Analysis
Central Limit Theorem
The primary operating characteristics of a product.
=sqrt((p*(1-p)/n)

20. What is Kaizen?
10 if Almost impossible to detect
Rapid improvement process.
The manager in charge of a process being improved in a Six Sigma project.
Used to create frequency distribution tally sheets

21. DOE
Linearity - normality - homoscedasticity - independence.
An assertion or conjecture concerning one or more populations
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
10 if Almost impossible to detect

22. What is the difference between Lean and Six Sigma?
Lean is waste reduction - Six Sigma is variation reduction.
Studying firms with the best performance in a particular area.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Pleasing to the senses.

23. Who first studied randomness in industrial processes
Walter A. Shewhart
To mentor/coach (and sometimes train) black belts.
Concluding there has not been an effect/change when there has.
A tool that shows where there is waste in a process.

24. In the Service Quality Gap Model - what is Gap 1?
Failure Modes and Effects Analysis
False - because each machine will have different natural tolerances.
The gap between what management thinks customers want and what customers really want.
5%

25. What are the three main categories of assignable cause?
Workers - machines - materials.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The gap between specifications and how service is performed.
Used to create frequency distribution tally sheets

26. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Outside.
A tool that shows the physical flows through a space.
68%
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

27. What is muda
Fractional factorial designs (orthogonal arrays)
Inventory = throughput x flow time.
Waste.
The manager in charge of a process being improved in a Six Sigma project.

28. What is the formula for standard deviation?
Variable.
=sqrt(Σ(x-x-bar)^2)/(n-1))
To do a capability study for a non-centered process.
Used to create frequency distribution tally sheets

29. What is poka yoke?
Brand image.
Mistake-proofing.
Fishbone - cause-and-effect diagram.
Because the mean and standard deviation are independent of each other.

30. Advantages of DOE
QFD
Lower skill requirements - faster - less chance for error.
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
Represents the behavior of a process

31. Effect ranking (Severity of the Defect)
10 for Hazardous without warning 1 for none
Through producer/consumer negotiation.
A tool that shows performance along key dimensions all at once.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

32. What percentage of a normal distribution lies above the mean?
Supplier - input - process - output - customer.
50%
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
To mentor/coach (and sometimes train) black belts.

33. What is Type II Error?
A random variable that summarizes the information from the sample(s).
Attribute.
Concluding there has not been an effect/change when there has.
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

34. Risk Priority Number RPN
The gap between what is promised and what is delivered.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
= yij - y(bar)i --> value minus sum of that treatment (of row)
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

35. Detection Criteria Ranking
To monitor a process when measurement by attribute is used.
No -- the variation also has to be random and "expected."
10 if Almost impossible to detect
Controlling quality at the source.

36. Define durability.
To monitor a process when measurement by attribute is used.
Supplier - input - process - output - customer.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Mean time to replacement.

37. What are the 5 Ss?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Sort - Set in Order - Shine - Standardize - Sustain
The Japanese national quality award.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

38. What is an affinity 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
A brainstorming tool that shows the connections between ideas.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Lean is waste reduction - Six Sigma is variation reduction.

39. What does the abbreviation LCL stand for?
To mentor/coach (and sometimes train) black belts.
Represents the behavior of a process
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Lower control limit.

40. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The number of standard deviations some value is from the mean.
Controlling quality at the source.
Lower skill requirements - faster - less chance for error.

41. Histogram by Hand
Mistake-proofing.
Is what induces the failure
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
Causes that lead to a particular effect.

42. Define features.
Pleasing to the senses.
Attribute.
The secondary characteristics of a product; "bells and whistles."
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

43. Define takt time.
50%
The cycle time required to meet demand.
Define - measure - analyze - design - verify.
Technical quality is the "what" of the service; functional quality is the "how."

44. Residual
0.9^3 or 72.9%
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
10 if Almost impossible to detect

45. List Garvin's eight dimensions of product quality.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Organize ideas into meaningful categories by recognizing their underlying similarity
Deming.

46. Test for Independence
Is what induces the failure
= 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
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
Is the consequence of the failure.

47. What does the abbreviation UCL stand for?
Financial - customer - internal process - innovation and learning.
Waste.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Upper control limit.

48. One factor at a time (OFAT)
100%
Method developed by Ishikawa to graphically display the causes of any given problem
Producer risk.
Observed variation in response is caused by the input

49. Test for constant variance
Shifts - Trends - Repeating patterns - Correlation with known events
To manage the Six Sigma project.
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.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

50. What does a project prioritization matrix do?
Fractional factorial designs (orthogonal arrays)
p-bar - the long-run percent defective.
Assigns scores to weighted criteria for each project under consideration.
Represents the behavior of a process