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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. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
Mean time to replacement.
To be a member of a Six Sigma project team.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

2. What does the abbreviation LCL stand for?
A random variable that summarizes the information from the sample(s).
Lower control limit.
Failure Modes and Effects Analysis
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

3. Uses of regression - Control
Initiated before or at design concept finalization
To obtain a certain desirable outcome from the process
Upper control limit.
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

4. What graphical tool is used to show the relationship between two numerical variables?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Is the way in which the failure is manifested.
A scatterplot.
The secondary characteristics of a product; "bells and whistles."

5. What are the three main categories of assignable cause?
To mentor/coach (and sometimes train) black belts.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Workers - machines - materials.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

6. Creating a Run Chart
Fewer good units to sell - increased variable cost/unit.
X-bar-bar
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Different types of defects are listed (used for Pareto chart)

7. Who developed the fishbone diagram?
Walter A. Shewhart
Kaoru Ishikawa.
Variable.
Blame.

8. Define benchmarking.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
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
Because the mean and standard deviation are independent of each other.
Studying firms with the best performance in a particular area.

9. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
To obtain a certain desirable outcome from the process
Before production starts
If the Response vs. Levels graph if the response lines are not parallel (crossing)
No -- the variation also has to be random and "expected."

10. What does a project prioritization matrix do?
3.4 (assuming 1.5 sigma shift in the mean)
Observed variation in response is caused by the input
Assigns scores to weighted criteria for each project under consideration.
Kaoru Ishikawa.

11. What is poka yoke?
The primary operating characteristics of a product.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Studying firms with the best performance in a particular area.
Mistake-proofing.

12. List two components of prevention cost.
No -- only if the process is also capable.
Mean time to replacement.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
A tool that shows performance along key dimensions all at once.

13. What is the role of a black belt?
To manage the Six Sigma project.
The US national quality award.
To obtain a certain desirable outcome from the process
Lower control limit.

14. Advantages of DOE
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).
A tool that shows where there is waste in a process.
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

15. Cause and Effect Diagrams
Supplier - input - process - output - customer.
Is the consequence of the failure.
Represents the behavior of a process
Method developed by Ishikawa to graphically display the causes of any given problem

16. Your production process meets customer specifications. Is your process in control?
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
Not necessarily.
50%
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).

17. Define durability.
Mean time to replacement.
The primary operating characteristics of a product.
=sqrt((p*(1-p)/n)
Pleasing to the senses.

18. The Test Statistic (TS)
A random variable that summarizes the information from the sample(s).
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
To do a capability study for a non-centered process.
Speed - courtesy - competence - and ease of repair.

19. Defect location check sheets
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The gap between what is promised and what is delivered.
Actual drawings - layouts - maps - etc which show where a defect occurs
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).

20. What quality tool formally incorporates the voice of the customer?
The cycle time required to meet demand.
A tool that shows where there is waste in a process.
Sampling for SPC is done real time.
QFD

21. In the Service Quality Gap Model - what is Gap 2?
Assigns scores to weighted criteria for each project under consideration.
The gap between what is promised and what is delivered.
Someone who is consistently against virtually everything.
The gap between what management thinks customers want and the process specifications.

22. For what is an x-bar chart used?
Variable.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
To monitor a process when measurement by variables is used.
No -- if it is not the same - it can only be worse!

23. When yields decrease - what are the two effects on contribution?
Fishbone - cause-and-effect diagram.
Blame.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Fewer good units to sell - increased variable cost/unit.

24. 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?
False - because each machine will have different natural tolerances.
50%
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Initiated before or at design concept finalization

25. What is the role of a master black belt?
Lower skill requirements - faster - less chance for error.
68%
To mentor/coach (and sometimes train) black belts.
Rapid improvement process.

26. What percentage of a normal distribution lies above the mean?
It looks to minimize the probability of a failure - or to minimize its effects
Outside.
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%

27. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Attribute.
To monitor a process when measurement by attribute is used.
Variable.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

28. What is the center line of an X-bar chart?
Mistake-proofing.
Technical quality is the "what" of the service; functional quality is the "how."
To obtain a certain desirable outcome from the process
X-bar-bar

29. Does it ever make sense to accept a job when a process is incapable?
Can't tell without a Range chart.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Is the way in which the failure is manifested.
Variable.

30. What does DMAIC stand for?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Defects Per Million Opportunities
Supplier - input - process - output - customer.
Define - measure - analyze - improve - control.

31. Define yield.
Financial - customer - internal process - innovation and learning.
Stratify a particular defect type according to logical criteria
Fractional factorial designs (orthogonal arrays)
The ratio of outputs to inputs; 1-scrap.

32. ANOVA

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33. What is the difference between the way sampling is done for SPC and for acceptance sampling?
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
They move closer to the center line.
Sampling for SPC is done real time.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

34. If you have calculated a Cpk - should you also calculate a Cp?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
A brainstorming tool that shows the connections between ideas.
= yij - y(bar)i --> value minus sum of that treatment (of row)

35. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Fitness for use.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Hold all input variables constant except one. Observe the response as you vary the single input.
Attribute

36. What is Value Stream Mapping?
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 tool that shows where there is waste in a process.
The gap between what is promised and what is delivered.
To do a capability study for a non-centered process.

37. What are the 5 Ss?
To monitor a process when measurement by attribute is used.
To be a member of a Six Sigma project team.
Attribute.
Sort - Set in Order - Shine - Standardize - Sustain

38. What is the Baldrige Award?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Fractional factorial designs (orthogonal arrays)
The US national quality award.
Blame.

39. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Method developed by Ishikawa to graphically display the causes of any given problem
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
100%
5%

40. List two appraisal costs.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
3.4 (assuming 1.5 sigma shift in the mean)
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

41. Define aesthetic quality.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Assigns scores to weighted criteria for each project under consideration.
Pleasing to the senses.
Variable.

42. TWO-DIMENTIONAL SCATTER PLOT
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
X-bar-bar
Concluding there has not been an effect/change when there has.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

43. Test for Independence
No -- if it is not the same - it can only be worse!
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
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
Mistake-proofing.

44. What are the four perspectives of the Balanced Scorecard?
Failure Modes and Effects Analysis
To be a member of a Six Sigma project team.
Financial - customer - internal process - innovation and learning.
Attribute.

45. Pareto Analysis
Someone who is consistently against virtually everything.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
False - because each machine will have different natural tolerances.
Financial - customer - internal process - innovation and learning.

46. In a Z table - what is Z?
The number of standard deviations some value is from the mean.
The cycle time required to meet demand.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Fishbone - cause-and-effect diagram.

47. Residual(eij)
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
= yij - y(bar)i --> value minus sum of that treatment (of row)
Method developed by Ishikawa to graphically display the causes of any given problem
Causes that lead to a particular effect.

48. Process check sheets
Used to create frequency distribution tally sheets
Speed - courtesy - competence - and ease of repair.
Taguchi
The primary operating characteristics of a product.

49. Effect ranking (Severity of the Defect)
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).
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 management thinks customers want and what customers really want.
10 for Hazardous without warning 1 for none

50. What are the four regression assumptions?
Upper control limit.
Causes that lead to a particular effect.
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
Linearity - normality - homoscedasticity - independence.