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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. Which type of SPC measurement is more precise - variable or attribute?
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
Variable.
Supplier - input - process - output - customer.
QFD

2. PFMEA
Can't tell without a Range chart.
Before production starts
5%
Failure Modes and Effects Analysis

3. Which quality guru developed the concept of loss to society?
Technical quality is the "what" of the service; functional quality is the "how."
Taguchi
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).
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

4. 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.
Shows the temporal flow of activities in a project network.
Organize ideas into meaningful categories by recognizing their underlying similarity

5. List two components of external failure.
The US national quality award.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
False - because each machine will have different natural tolerances.
Shows the temporal flow of activities in a project network.

6. FMEA
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
= 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
Conformance to specifications.
The gap between what management thinks customers want and the process specifications.

7. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Sort - Set in Order - Shine - Standardize - Sustain
No -- the variation also has to be random and "expected."
X-bar-bar
Prevention - appraisal - internal failure - external failure.

8. In the Service Quality Gap Model - what is Gap 4?
Waste.
An assertion or conjecture concerning one or more populations
The gap between what is promised and what is delivered.
To monitor a process when measurement by attribute is used.

9. Define performance quality.
The primary operating characteristics of a product.
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
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
It looks to minimize the probability of a failure - or to minimize its effects

10. What is Type II Error?
Different types of defects are listed (used for Pareto chart)
Concluding there has not been an effect/change when there has.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Hold all input variables constant except one. Observe the response as you vary the single input.

11. What are the 5 Ss?
Sort - Set in Order - Shine - Standardize - Sustain
X-bar-bar
Studying firms with the best performance in a particular area.
The primary operating characteristics of a product.

12. If you have calculated a Cpk - should you also calculate a Cp?
The gap between what customers expect and the service they receive.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Deming.
A tool that shows the physical flows through a space.

13. In the Service Quality Gap Model - what is Gap 3?
The secondary characteristics of a product; "bells and whistles."
Lower skill requirements - faster - less chance for error.
The gap between specifications and how service is performed.
Prevention - appraisal - internal failure - external failure.

14. Uses of regression - Control
The degree to which a product meets pre-established standards.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
To obtain a certain desirable outcome from the process
Waste.

15. If a Cp shows that a process is not capable - should you calculate Cpk?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Mean time to replacement.
No -- if it is not the same - it can only be worse!
= yij - y(bar)i --> value minus sum of that treatment (of row)

16. DFMEA
Define - measure - analyze - design - verify.
Lean (or JIT).
Walter A. Shewhart
Initiated before or at design concept finalization

17. What is CTQ?
Someone who is consistently against virtually everything.
No -- only if the process is also capable.
Rapid improvement process.
Critical to quality.

18. What is the role of a master black belt?
Variable.
Upper control limit.
Attribute.
To mentor/coach (and sometimes train) black belts.

19. One factor at a time (OFAT)
Observed variation in response is caused by the input
Inventory = throughput x flow time.
QFD
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

20. Define yield.
Before production starts
Taguchi
Not necessarily.
The ratio of outputs to inputs; 1-scrap.

21. What is an affinity diagram?
Because the mean and standard deviation are independent of each other.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
3.4 (assuming 1.5 sigma shift in the mean)
A brainstorming tool that shows the connections between ideas.

22. In the Service Quality Gap Model - what is Gap 2?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
The gap between what management thinks customers want and the process specifications.
The cycle time required to meet demand.

23. What is muda
Lower control limit.
The secondary characteristics of a product; "bells and whistles."
Waste.
To monitor a process when measurement by variables is used.

24. Taguchi's experimental designs are of this type.
QFD
Fractional factorial designs (orthogonal arrays)
Consumer risk.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

25. Define conformance quality.
The degree to which a product meets pre-established standards.
No -- if it is not the same - it can only be worse!
Define - measure - analyze - design - verify.
10 for Hazardous without warning 1 for none

26. For what is an x-bar chart used?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
To monitor a process when measurement by variables is used.
A tool that shows where there is waste in a process.
False - because each machine will have different natural tolerances.

27. Your production process meets customer specifications. Is your process in control?
Not necessarily.
Lower control limit.
Organize ideas into meaningful categories by recognizing their underlying similarity
Blame.

28. What is the difference between Lean and Six Sigma?
Lean is waste reduction - Six Sigma is variation reduction.
= yij - y(bar)i --> value minus sum of that treatment (of row)
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Taguchi

29. What is a histogram?
Concluding there has not been an effect/change when there has.
Causes that lead to a particular effect.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Sort - Set in Order - Shine - Standardize - Sustain

30. List two components of prevention cost.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
An assertion or conjecture concerning one or more populations
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
To mentor/coach (and sometimes train) black belts.

31. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
Waste.
It's good -- but it's still out of control!
Outside.

32. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
F_alpha - df(tr) - df (error)
Conformance to specifications.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Controlling quality at the source.

33. In the Service Quality Gap Model - what is Gap 1?
Organize ideas into meaningful categories by recognizing their underlying similarity
A scatterplot.
The gap between what management thinks customers want and what customers really want.
The US national quality award.

34. What is Type 1 Error?
Sort - Set in Order - Shine - Standardize - Sustain
Is what induces the failure
Hold all input variables constant except one. Observe the response as you vary the single input.
Concluding there has been an effect/change when there has not.

35. List Garvin's eight dimensions of product quality.
Outside.
Causes that lead to a particular effect.
A brainstorming tool that shows the connections between ideas.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

36. Disadvantages of DOE

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37. Residual(eij)
Defects Per Million Opportunities
= yij - y(bar)i --> value minus sum of that treatment (of row)
A scatterplot.
= 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

38. Process check sheets
Stratify a particular defect type according to logical criteria
Used to create frequency distribution tally sheets
Different types of defects are listed (used for Pareto chart)
Producer risk.

39. Defect location check sheets
Actual drawings - layouts - maps - etc which show where a defect occurs
Mean time to replacement.
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
Upper control limit.

40. In Juran's Cost of Quality model - which categories of costs balance which other categories?
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
Prevention and appraisal costs are balanced against internal and external failure.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Technical quality is the "what" of the service; functional quality is the "how."

41. What is a CAVE man?
Not necessarily.
Fitness for use.
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:
Someone who is consistently against virtually everything.

42. DOE
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Consumer risk.
It's good -- but it's still out of control!
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

43. Non-random patterns (Run Charts)
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Scrap - rework - retest - downtime - yield losses - disposition costs.
Shifts - Trends - Repeating patterns - Correlation with known events
False - because each machine will have different natural tolerances.

44. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
95%
Causes that lead to a particular effect.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

45. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
To monitor a process when measurement by attribute is used.
Concluding there has been an effect/change when there has not.
Outside.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

46. TWO-DIMENTIONAL SCATTER PLOT
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
To be a member of a Six Sigma project team.
Blame.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

47. Affinity Diagrams
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Look for the assignable cause of non-random variation.
Define - measure - analyze - improve - control.

48. What are the four perspectives of the Balanced Scorecard?
Outside.
Financial - customer - internal process - innovation and learning.
Large enough to find two of the attribute - on average.
Blame.

49. The Test Statistic (TS)
The US national quality award.
A random variable that summarizes the information from the sample(s).
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:
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

50. What is process capability?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
= 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
10 if Almost impossible to detect
The ability of a process to consistently meet customer specifications.