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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. What is Type 1 Error?
Concluding there has been an effect/change when there has not.
Attribute.
The House of Quality.
The manager in charge of a process being improved in a Six Sigma project.

2. What does SIPOC stand for?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The House of Quality.
Defects Per Million Opportunities
Supplier - input - process - output - customer.

3. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
The target number of standard deviations from the mean for specifications.
Outside.
Consumer risk.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

4. If you can only collect categorical data - what type of SPC charting can you do?
Through producer/consumer negotiation.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Attribute.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

5. What does Crosby say about benchmarking?
The ability of a process to consistently meet customer specifications.
To mentor/coach (and sometimes train) black belts.
Consumer risk.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

6. Histogram by Hand
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
Taguchi
Organize ideas into meaningful categories by recognizing their underlying similarity

7. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
99.73%
It looks to minimize the probability of a failure - or to minimize its effects
The US national quality award.
Can't tell without a Range chart.

8. TWO-DIMENTIONAL SCATTER PLOT
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Variable.
F_alpha - df(tr) - df (error)

9. What are two other names for an Ishikawa diagram?
A scatterplot.
X-bar-bar
The manager in charge of a process being improved in a Six Sigma project.
Fishbone - cause-and-effect diagram.

10. What is a CAVE man?
Someone who is consistently against virtually everything.
Consumer risk.
F_alpha - df(tr) - df (error)
A random variable that summarizes the information from the sample(s).

11. FMEA
Prevention and appraisal costs are balanced against internal and external failure.
Define - measure - analyze - improve - 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
Upper control limit.

12. Who first studied randomness in industrial processes
Walter A. Shewhart
A time series plot.
Large enough to find two of the attribute - on average.
10 if Almost impossible to detect

13. Effect ranking (Severity of the Defect)
A tool that shows where there is waste in a process.
10 for Hazardous without warning 1 for none
A time series plot.
A random variable that summarizes the information from the sample(s).

14. List two components of external failure.
Sort - Set in Order - Shine - Standardize - Sustain
Consumer risk.
Concluding there has not been an effect/change when there has.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

15. What is process capability?
What the value of the dependent variable is when the independent variable is zero.
A descending order-sorted bar chart with a cumulative percentage line.
A tool that shows where there is waste in a process.
The ability of a process to consistently meet customer specifications.

16. DFMEA
Pleasing to the senses.
Initiated before or at design concept finalization
Lower skill requirements - faster - less chance for error.
Waste.

17. F value
= yij - y(bar)i --> value minus sum of that treatment (of row)
F_alpha - df(tr) - df (error)
Walter A. Shewhart
Kaoru Ishikawa.

18. When is Cpk used?
To do a capability study for a non-centered process.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
They move closer to the center line.

19. Define features.
The secondary characteristics of a product; "bells and whistles."
Blame.
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).
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.

20. The Test Statistic (TS)
A random variable that summarizes the information from the sample(s).
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Blame.
Outside.

21. What happens to control limits on an SPC chart when sample size is increased?
A scatterplot.
The ability of a process to consistently meet customer specifications.
They move closer to the center line.
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. What type of risk is associated with Type 1 Error?
QFD
Producer risk.
Workers - machines - materials.
Waste.

23. Detection Criteria Ranking
10 if Almost impossible to detect
No -- only if the process is also capable.
To mentor/coach (and sometimes train) black belts.
The manager in charge of a process being improved in a Six Sigma project.

24. Residual(eij)
To mentor/coach (and sometimes train) black belts.
Assigns scores to weighted criteria for each project under consideration.
Fractional factorial designs (orthogonal arrays)
= yij - y(bar)i --> value minus sum of that treatment (of row)

25. What is an affinity diagram?
Concluding there has not been an effect/change when there has.
Inventory = throughput x flow time.
A brainstorming tool that shows the connections between ideas.
Through producer/consumer negotiation.

26. What is the role of a master black belt?
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
To mentor/coach (and sometimes train) black belts.
The cycle time required to meet demand.

27. Define takt time.
50%
The cycle time required to meet demand.
To obtain a certain desirable outcome from the process
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

28. In the Service Quality Gap Model - what is Gap 3?
To manage the Six Sigma project.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The gap between specifications and how service is performed.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

29. One factor at a time (OFAT)
Look for the assignable cause of non-random variation.
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:
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
Hold all input variables constant except one. Observe the response as you vary the single input.

30. In a regression - what does the standard error of the estimate tell you?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Sort - Set in Order - Shine - Standardize - Sustain
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Controlling quality at the source.

31. Define product reliability.
Central Limit Theorem
Concluding there has not been an effect/change when there has.
The House of Quality.
Mean time to failure.

32. Pareto Analysis
Waste.
Assigns scores to weighted criteria for each project under consideration.
Is the consequence of the failure.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

33. What is a Pareto chart?
Producer risk.
The House of Quality.
99.73%
A descending order-sorted bar chart with a cumulative percentage line.

34. 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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35. What is the formula for the standard deviation of a proportion?
Before production starts
The secondary characteristics of a product; "bells and whistles."
=sqrt((p*(1-p)/n)
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

36. Simple Regression Analysis (one factor regression model)
= 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 House of Quality.
Sort - Set in Order - Shine - Standardize - Sustain
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

37. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
Define - measure - analyze - improve - control.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Used to create frequency distribution tally sheets

38. What does a project prioritization matrix do?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Lower control limit.
Assigns scores to weighted criteria for each project under consideration.
Fishbone - cause-and-effect diagram.

39. What is the Deming Prize?
Attribute
The Japanese national quality award.
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).

40. In the Service Quality Gap Model - what is Gap 4?
Initiated before or at design concept finalization
The gap between what is promised and what is delivered.
5%
A diagram that shows the relationships between activities in a project network.

41. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
The manager in charge of a process being improved in a Six Sigma project.
Sort - Set in Order - Shine - Standardize - Sustain
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
68%

42. Defect check sheets
The ability of a process to consistently meet customer specifications.
Brand image.
F_alpha - df(tr) - df (error)
Different types of defects are listed (used for Pareto chart)

43. In Juran's Cost of Quality model - which categories of costs balance which other categories?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Prevention and appraisal costs are balanced against internal and external failure.
p-bar - the long-run percent defective.
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).

44. List two components of prevention cost.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
They move closer to the center line.
Prevention and appraisal costs are balanced against internal and external failure.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

45. What quality guru emphasizes management as a system?
Walter A. Shewhart
Deming.
10 if Almost impossible to detect
Brand image.

46. Risk Priority Number RPN
Critical to quality.
No -- if it is not the same - it can only be worse!
A diagram that shows the relationships between activities in a project network.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

47. What are the 5 Ss?
Variable.
Sort - Set in Order - Shine - Standardize - Sustain
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Waste.

48. What is the difference between the way sampling is done for SPC and for acceptance sampling?
99.73%
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Sampling for SPC is done real time.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

49. Why do you need two control charts for variables SPC?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The gap between what management thinks customers want and the process specifications.
It looks to minimize the probability of a failure - or to minimize its effects
Because the mean and standard deviation are independent of each other.

50. List two appraisal costs.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Failure Modes and Effects Analysis
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions