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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. Test for Independence
The gap between what management thinks customers want and what customers really want.
Failure Modes and Effects Analysis
10 if Almost impossible to detect
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

2. If a Cp shows that a process is not capable - should you calculate Cpk?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(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:
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
No -- if it is not the same - it can only be worse!

3. Presence of interaction effect
10 if Almost impossible to detect
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Different types of defects are listed (used for Pareto chart)

4. Uses of regression
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Rapid improvement process.
95%
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

5. What is an affinity diagram?
Observed variation in response is caused by the input
A brainstorming tool that shows the connections between ideas.
Assigns scores to weighted criteria for each project under consideration.
To manage the Six Sigma project.

6. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Financial - customer - internal process - innovation and learning.
Lower control limit.
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
Outside.

7. Definition of Interaction
Define - measure - analyze - improve - control.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Large enough to find two of the attribute - on average.
The gap between specifications and how service is performed.

8. DOE
Technical quality is the "what" of the service; functional quality is the "how."
Organize ideas into meaningful categories by recognizing their underlying similarity
Because the mean and standard deviation are independent of each other.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

9. Define product reliability.
Method developed by Ishikawa to graphically display the causes of any given problem
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)
Mean time to failure.

10. Test for constant variance
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.
Fractional factorial designs (orthogonal arrays)
False - because each machine will have different natural tolerances.
Producer risk.

11. Why do you need two control charts for variables SPC?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
= 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
Because the mean and standard deviation are independent of each other.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

12. Risk Priority Number RPN
Controlling quality at the source.
Blame.
Actual drawings - layouts - maps - etc which show where a defect occurs
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

13. What is a network diagram?
=sqrt(Σ(x-x-bar)^2)/(n-1))
Define - measure - analyze - improve - control.
To do a capability study for a non-centered process.
A diagram that shows the relationships between activities in a project network.

14. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
The gap between what management thinks customers want and what customers really want.
Technical quality is the "what" of the service; functional quality is the "how."
The ability of a process to consistently meet customer specifications.

15. Define yield.
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
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Scrap - rework - retest - downtime - yield losses - disposition costs.
The ratio of outputs to inputs; 1-scrap.

16. Define performance quality.
=sqrt(Σ(x-x-bar)^2)/(n-1))
A tool that shows the physical flows through a space.
To monitor a process when measurement by attribute is used.
The primary operating characteristics of a product.

17. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
F_alpha - df(tr) - df (error)
10 if Almost impossible to detect
100%
To manage the Six Sigma project.

18. Manual Test for Nomality
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
The manager in charge of a process being improved in a Six Sigma project.
Assigns scores to weighted criteria for each project under consideration.
Attribute

19. What does the abbreviation LCL stand for?
Lower control limit.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
A tool that shows where there is waste in a process.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

20. What is the center line of an X-bar chart?
Waste.
X-bar-bar
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
It's good -- but it's still out of control!

21. What is the role of a green belt?
To be a member of a Six Sigma project team.
The degree to which a product meets pre-established standards.
The secondary characteristics of a product; "bells and whistles."
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

22. In the Service Quality Gap Model - what is Gap 3?
Before production starts
= 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 ratio of outputs to inputs; 1-scrap.
The gap between specifications and how service is performed.

23. If a three-stage process has 90% yields at each stage - what is the overall yield?
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.
0.9^3 or 72.9%
To be a member of a Six Sigma project team.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

24. Failure effect
Brand image.
To monitor a process when measurement by attribute is used.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Is the consequence of the failure.

25. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
68%
0.9^3 or 72.9%
Lower skill requirements - faster - less chance for error.
Fractional factorial designs (orthogonal arrays)

26. Which quality guru developed the concept of loss to society?
The cycle time required to meet demand.
X-bar-bar
Taguchi
Blame.

27. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Method developed by Ishikawa to graphically display the causes of any given problem
A tool that shows performance along key dimensions all at once.
Sampling for SPC is done real time.
99.73%

28. What percentage of a normal distribution lies above the mean?
50%
The gap between what customers expect and the service they receive.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

29. Stratified defect check sheets
Stratify a particular defect type according to logical criteria
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.
F_alpha - df(tr) - df (error)

30. What is muda
Financial - customer - internal process - innovation and learning.
Waste.
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
False - because each machine will have different natural tolerances.

31. What does a project prioritization matrix do?
Assigns scores to weighted criteria for each project under consideration.
10 for Hazardous without warning 1 for none
To monitor a process when measurement by variables is used.
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

32. What quality tool formally incorporates the voice of the customer?
Observed variation in response is caused by the input
Rapid improvement process.
QFD
Producer risk.

33. Explain the difference between technical and functional service quality.
Stratify a particular defect type according to logical criteria
Technical quality is the "what" of the service; functional quality is the "how."
p-bar - the long-run percent defective.
Failure Modes and Effects Analysis

34. With Six Sigma capability - how many defects per million opportunities would you see?
Walter A. Shewhart
Prevention and appraisal costs are balanced against internal and external failure.
3.4 (assuming 1.5 sigma shift in the mean)
Used to create frequency distribution tally sheets

35. What is the role of a master black belt?
The secondary characteristics of a product; "bells and whistles."
To mentor/coach (and sometimes train) black belts.
95%
No -- only if the process is also capable.

36. In a Z table - what is Z?
Conformance to specifications.
Consumer risk.
The number of standard deviations some value is from the mean.
To monitor a process when measurement by variables is used.

37. Based on what principal can we use the normal distribution assumptions for SPC?
p-bar - the long-run percent defective.
Defects Per Million Opportunities
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Central Limit Theorem

38. Name the structure associated with Quality Function Deployment.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The House of Quality.
Is the way in which the failure is manifested.
The manager in charge of a process being improved in a Six Sigma project.

39. What is a run chart?
The gap between what management thinks customers want and the process specifications.
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
A time series plot.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

40. What is written on the "spines" of a fishbone diagram?
Causes that lead to a particular effect.
Hold all input variables constant except one. Observe the response as you vary the single input.
Failure Modes and Effects Analysis
Look for the assignable cause of non-random variation.

41. What is DMADV?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Waste.
Define - measure - analyze - design - verify.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

42. What is Value Stream Mapping?
Workers - machines - materials.
A tool that shows where there is waste in a process.
They move closer to the center line.
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

43. Define benchmarking.
Studying firms with the best performance in a particular area.
Variable.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Not necessarily.

44. What does DMAIC stand for?
Failure Modes and Effects Analysis
To obtain a certain desirable outcome from the process
=sqrt((p*(1-p)/n)
Define - measure - analyze - improve - control.

45. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
100%
Conformance to specifications.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Upper control limit.

46. What are the four categories of costs in Juran's framework?
Blame.
Prevention - appraisal - internal failure - external failure.
Upper control limit.
Defects Per Million Opportunities

47. 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).
Variable.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

48. Histogram by Hand
It looks to minimize the probability of a failure - or to minimize its effects
To monitor a process when measurement by variables is used.
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
Walter A. Shewhart

49. Regression Analysis
A scatterplot.
The gap between specifications and how service is performed.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
A random variable that summarizes the information from the sample(s).

50. What happens to control limits on an SPC chart when sample size is increased?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Attribute.
An assertion or conjecture concerning one or more populations
They move closer to the center line.