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Six Sigma

Subjects : certifications, six-sigma, business-skills

Instructions:

Answer 50 questions in 15 minutes.
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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 is process capability?
Critical to quality.
The ability of a process to consistently meet customer specifications.
Assigns scores to weighted criteria for each project under consideration.
The Japanese national quality award.

2. Define aesthetic quality.
It looks to minimize the probability of a failure - or to minimize its effects
Pleasing to the senses.
= 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
A time series plot.

3. In the Service Quality Gap Model - what is Gap 3?
The gap between what is promised and what is delivered.
100%
The gap between specifications and how service is performed.
To manage the Six Sigma project.

4. What quality guru emphasizes management as a system?
Shifts - Trends - Repeating patterns - Correlation with known events
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
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
Deming.

5. What type of risk is associated with Type 1 Error?
Producer risk.
The cycle time required to meet demand.
QFD
Blame.

6. Process check sheets
Deming.
Large enough to find two of the attribute - on average.
Used to create frequency distribution tally sheets
Define - measure - analyze - improve - control.

7. What does the abbreviation LCL stand for?
Blame.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Can't tell without a Range chart.
Lower control limit.

8. For what is a p-chart used?
To monitor a process when measurement by attribute is used.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
To mentor/coach (and sometimes train) black belts.
A tool that shows where there is waste in a process.

9. Why do you need two control charts for variables SPC?
Is the way in which the failure is manifested.
Because the mean and standard deviation are independent of each other.
Financial - customer - internal process - innovation and learning.
Fitness for use.

10. What is the center line of a p-chart?
Organize ideas into meaningful categories by recognizing their underlying similarity
p-bar - the long-run percent defective.
Large enough to find two of the attribute - on average.
Observed variation in response is caused by the input

11. What is the difference between Lean and Six Sigma?
Taguchi
Shifts - Trends - Repeating patterns - Correlation with known events
Lean is waste reduction - Six Sigma is variation reduction.
What the value of the dependent variable is when the independent variable is zero.

12. What is the center line of an X-bar chart?
X-bar-bar
Method developed by Ishikawa to graphically display the causes of any given problem
Mistake-proofing.
p-bar - the long-run percent defective.

13. List two appraisal costs.
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
Upper control limit.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
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

14. Simple Regression Analysis (one factor regression model)
No -- only if the process is also capable.
The gap between what management thinks customers want and the process specifications.
Studying firms with the best performance in a particular area.
= 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

15. Define durability.
Inventory = throughput x flow time.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A tool that shows the physical flows through a space.
Mean time to replacement.

16. Who developed the fishbone diagram?
The gap between what is promised and what is delivered.
Kaoru Ishikawa.
X-bar-bar
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

17. Failure Mode
Is the way in which the failure is manifested.
Workers - machines - materials.
To do a capability study for a non-centered process.
Observed variation in response is caused by the input

18. Your production process meets customer specifications. Is your process in control?
The secondary characteristics of a product; "bells and whistles."
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
Not necessarily.
Conformance to specifications.

19. If a Cp shows that a process is not capable - should you calculate Cpk?
Conformance to specifications.
The degree to which a product meets pre-established standards.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
No -- if it is not the same - it can only be worse!

20. What are the Five Dimensions of Service Quality?
Critical to quality.
Blame.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
0.9^3 or 72.9%

21. Residual(eij)
Defects Per Million Opportunities
Is the way in which the failure is manifested.
Fewer good units to sell - increased variable cost/unit.
= yij - y(bar)i --> value minus sum of that treatment (of row)

22. In the Service Quality Gap Model - what is Gap 5?
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
The gap between what customers expect and the service they receive.
The gap between what is promised and what is delivered.
Blame.

23. What is a Gage R&R?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
99.73%
Studying firms with the best performance in a particular area.
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).

24. Defect check sheets
Different types of defects are listed (used for Pareto chart)
= yij - y(bar)i --> value minus sum of that treatment (of row)
99.73%
Lower skill requirements - faster - less chance for error.

25. What is a dashboard?
A tool that shows performance along key dimensions all at once.
To do a capability study for a non-centered process.
Consumer risk.
To be a member of a Six Sigma project team.

26. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Walter A. Shewhart
It looks to minimize the probability of a failure - or to minimize its effects

27. What happens to control limits on an SPC chart when sample size is increased?
They move closer to the center line.
Define - measure - analyze - improve - control.
= yij - y(bar)i --> value minus sum of that treatment (of row)
A tool that shows performance along key dimensions all at once.

28. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
95%
=sqrt((p*(1-p)/n)
Rapid improvement process.
What the value of the dependent variable is when the independent variable is zero.

29. Advantages of DOE
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Conformance to specifications.
Not necessarily.
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

30. There are two milling machines in the shop. Data has been collected on one to compute control limits for both. This is acceptable SPC practice - true or false and why?
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).
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
False - because each machine will have different natural tolerances.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

31. What is a network diagram?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
It's good -- but it's still out of control!
A diagram that shows the relationships between activities in a project network.
Concluding there has not been an effect/change when there has.

32. Creating a Run Chart
Deming.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
p-bar - the long-run percent defective.

33. Define features.
A brainstorming tool that shows the connections between ideas.
The secondary characteristics of a product; "bells and whistles."
Blame.
Failure Modes and Effects Analysis

34. List Garvin's eight dimensions of product quality.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Producer risk.
To be a member of a Six Sigma project team.
Assigns scores to weighted criteria for each project under consideration.

35. What is the role of a green belt?
Studying firms with the best performance in a particular area.
It looks to minimize the probability of a failure - or to minimize its effects
To be a member of a Six Sigma project team.
Fitness for use.

36. What is Type II Error?
A diagram that shows the relationships between activities in a project network.
Concluding there has not been an effect/change when there has.
Through producer/consumer negotiation.
Lower control limit.

37. What is DMADV?
Is what induces the failure
An assertion or conjecture concerning one or more populations
Define - measure - analyze - design - verify.
Stratify a particular defect type according to logical criteria

38. Affinity Diagrams
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Organize ideas into meaningful categories by recognizing their underlying similarity
It's good -- but it's still out of control!
If the Response vs. Levels graph if the response lines are not parallel (crossing)

39. Explain the difference between technical and functional service quality.
Conformance to specifications.
Technical quality is the "what" of the service; functional quality is the "how."
68%
Method developed by Ishikawa to graphically display the causes of any given problem

40. Regression
Scrap - rework - retest - downtime - yield losses - disposition costs.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The House of Quality.
Represents the behavior of a process

41. What is a CAVE man?
Someone who is consistently against virtually everything.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
To monitor a process when measurement by attribute is used.
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:

42. Define benchmarking.
50%
A tool that shows the physical flows through a space.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Studying firms with the best performance in a particular area.

43. Define serviceability.
Speed - courtesy - competence - and ease of repair.
Variable.
Supplier - input - process - output - customer.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

44. In the Service Quality Gap Model - what is Gap 2?
The gap between what management thinks customers want and the process specifications.
To do a capability study for a non-centered process.
Hold all input variables constant except one. Observe the response as you vary the single input.
Deming.

45. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Upper control limit.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Mean time to replacement.
Outside.

46. To what does the Six in Six Sigma relate?
Fitness for use.
The target number of standard deviations from the mean for specifications.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
A tool that shows performance along key dimensions all at once.

47. DFMEA
Initiated before or at design concept finalization
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
Is the consequence of the failure.
=sqrt((p*(1-p)/n)

48. What are the four categories of costs in Juran's framework?
Someone who is consistently against virtually everything.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Prevention - appraisal - internal failure - external failure.
To be a member of a Six Sigma project team.

49. What is Jidoka?
Upper control limit.
Controlling quality at the source.
Is what induces the failure
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

50. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
10 for Hazardous without warning 1 for none
Fewer good units to sell - increased variable cost/unit.
Mean time to replacement.

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Six Sigma

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