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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. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Waste.
No -- if it is not the same - it can only be worse!

2. What is Kaizen?
Rapid improvement process.
It looks to minimize the probability of a failure - or to minimize its effects
The gap between what customers expect and the service they receive.
X-bar-bar

3. What does SIPOC stand for?
Central Limit Theorem
Lower control limit.
Supplier - input - process - output - customer.
Look for the assignable cause of non-random variation.

4. What is the role of a black belt?
Blame.
To manage the Six Sigma project.
Failure Modes and Effects Analysis
A time series plot.

5. Who is a process owner?
A tool that shows the physical flows through a space.
Lower control limit.
Financial - customer - internal process - innovation and learning.
The manager in charge of a process being improved in a Six Sigma project.

6. What are two other names for an Ishikawa diagram?
Fishbone - cause-and-effect diagram.
The ratio of outputs to inputs; 1-scrap.
Represents the behavior of a process
100%

7. You have been plotting sample means on an x-bar chart and all points indicate normal - expected variation. Is the process in control?

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8. List Garvin's eight dimensions of product quality.
Prevention - appraisal - internal failure - external failure.
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
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
False - because each machine will have different natural tolerances.

9. Defect location check sheets
=sqrt((p*(1-p)/n)
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Fitness for use.
Actual drawings - layouts - maps - etc which show where a defect occurs

10. What is process capability?
Lower skill requirements - faster - less chance for error.
= 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
=sqrt(Σ(x-x-bar)^2)/(n-1))
The ability of a process to consistently meet customer specifications.

11. What is Little's Law?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Inventory = throughput x flow time.
A time series plot.
What the value of the dependent variable is when the independent variable is zero.

12. Which type of SPC measurement is more precise - variable or attribute?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Variable.
Workers - machines - materials.
Is the consequence of the failure.

13. In a regression - what does the p value of F tell you?
Linearity - normality - homoscedasticity - independence.
They move closer to the center line.
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).
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

14. What is written on the "spines" of a fishbone diagram?
Causes that lead to a particular effect.
Look for the assignable cause of non-random variation.
To monitor a process when measurement by attribute is used.
The gap between what management thinks customers want and the process specifications.

15. List two components of prevention cost.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Someone who is consistently against virtually everything.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
5%

16. Effect ranking (Severity of the Defect)
10 for Hazardous without warning 1 for none
If the Response vs. Levels graph if the response lines are not parallel (crossing)
What the value of the dependent variable is when the independent variable is zero.
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

17. In a regression - what does R-square tell you?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
No -- the variation also has to be random and "expected."
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The gap between what is promised and what is delivered.

18. Complete this quality phrase: 'Fix the process - not the _____.'
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
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
Blame.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

19. What does the abbreviation UCL stand for?
A brainstorming tool that shows the connections between ideas.
Shifts - Trends - Repeating patterns - Correlation with known events
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
Upper control limit.

20. In Juran's Cost of Quality model - which categories of costs balance which other categories?
10 if Almost impossible to detect
Prevention - appraisal - internal failure - external failure.
Define - measure - analyze - design - verify.
Prevention and appraisal costs are balanced against internal and external failure.

21. What type of risk is associated with Type II Error?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Consumer risk.
Financial - customer - internal process - innovation and learning.
Pleasing to the senses.

22. What is an affinity diagram?
A descending order-sorted bar chart with a cumulative percentage line.
A brainstorming tool that shows the connections between ideas.
Prevention and appraisal costs are balanced against internal and external failure.
Mean time to replacement.

23. FMEA
It looks to minimize the probability of a failure - or to minimize its effects
Large enough to find two of the attribute - on average.
Concluding there has not been an effect/change when there has.
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

24. Residual(eij)
Hold all input variables constant except one. Observe the response as you vary the single input.
It looks to minimize the probability of a failure - or to minimize its effects
Represents the behavior of a process
= yij - y(bar)i --> value minus sum of that treatment (of row)

25. In the Service Quality Gap Model - what is Gap 1?
The gap between what management thinks customers want and what customers really want.
No -- if it is not the same - it can only be worse!
Speed - courtesy - competence - and ease of repair.
3.4 (assuming 1.5 sigma shift in the mean)

26. For what is a p-chart used?
To monitor a process when measurement by attribute is used.
Defects Per Million Opportunities
Producer risk.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

27. Defect check sheets
Sampling for SPC is done real time.
Different types of defects are listed (used for Pareto chart)
Mean time to replacement.
p-bar - the long-run percent defective.

28. What are the four categories of costs in Juran's framework?
A brainstorming tool that shows the connections between ideas.
The US national quality award.
Prevention - appraisal - internal failure - external failure.
Controlling quality at the source.

29. In the Service Quality Gap Model - what is Gap 5?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The cycle time required to meet demand.
The gap between what customers expect and the service they receive.
Is what induces the failure

30. In the Service Quality Gap Model - what is Gap 3?
Mean time to failure.
The gap between specifications and how service is performed.
Critical to quality.
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).

31. Define features.
The secondary characteristics of a product; "bells and whistles."
Linearity - normality - homoscedasticity - independence.
Initiated before or at design concept finalization
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

32. What is FMEA?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
A tool that shows the physical flows through a space.
Failure Modes and Effects Analysis
No -- if it is not the same - it can only be worse!

33. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
A brainstorming tool that shows the connections between ideas.
Kaoru Ishikawa.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

34. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
The gap between what is promised and what is delivered.
Lean (or JIT).
Mistake-proofing.
68%

35. Failure Mode
Producer risk.
Method developed by Ishikawa to graphically display the causes of any given problem
Is the way in which the failure is manifested.
The primary operating characteristics of a product.

36. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Fractional factorial designs (orthogonal arrays)
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
95%
To monitor a process when measurement by attribute is used.

37. List two components of internal failure.
Actual drawings - layouts - maps - etc which show where a defect occurs
99.73%
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
Scrap - rework - retest - downtime - yield losses - disposition costs.

38. What is Type II Error?
To mentor/coach (and sometimes train) black belts.
Concluding there has not been an effect/change when there has.
Mistake-proofing.
The secondary characteristics of a product; "bells and whistles."

39. What is a dashboard?
They move closer to the center line.
3.4 (assuming 1.5 sigma shift in the mean)
A tool that shows performance along key dimensions all at once.
A diagram that shows the relationships between activities in a project network.

40. List two components of external failure.
Conformance to specifications.
10 if Almost impossible to detect
Can't tell without a Range chart.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

41. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Concluding there has been an effect/change when there has not.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Attribute
The number of standard deviations some value is from the mean.

42. Define product reliability.
Fishbone - cause-and-effect diagram.
3.4 (assuming 1.5 sigma shift in the mean)
Mean time to failure.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

43. What is the Deming Prize?
The Japanese national quality award.
3.4 (assuming 1.5 sigma shift in the mean)
The cycle time required to meet demand.
A tool that shows where there is waste in a process.

44. 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?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
To mentor/coach (and sometimes train) black belts.
False - because each machine will have different natural tolerances.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

45. What is the 5S model?
Shows the temporal flow of activities in a project network.
Blame.
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
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

46. What is muda
Define - measure - analyze - design - verify.
Waste.
A descending order-sorted bar chart with a cumulative percentage line.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

47. FMEA
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
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
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

48. If a Cp shows that a process is not capable - should you calculate Cpk?
No -- if it is not the same - it can only be worse!
Central Limit Theorem
To monitor a process when measurement by attribute is used.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

49. What graphical tool is used to show the relationship between two numerical variables?
A scatterplot.
Upper control limit.
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
The gap between what management thinks customers want and the process specifications.

50. List two appraisal costs.
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
Fewer good units to sell - increased variable cost/unit.
Fishbone - cause-and-effect diagram.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed