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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 a Gantt chart?
Variable.
Shows the temporal flow of activities in a project network.
Fishbone - cause-and-effect diagram.
Organize ideas into meaningful categories by recognizing their underlying similarity

2. Define performance quality.
Defects Per Million Opportunities
To monitor a process when measurement by attribute is used.
The primary operating characteristics of a product.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

3. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
Pleasing to the senses.
A random variable that summarizes the information from the sample(s).
Used to create frequency distribution tally sheets

4. What is the role of a green belt?
A tool that shows performance along key dimensions all at once.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
To be a member of a Six Sigma project team.

5. Disadvantages of DOE

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6. To what does the Six in Six Sigma relate?
X-bar-bar
The target number of standard deviations from the mean for specifications.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
The gap between what is promised and what is delivered.

7. What is the role of a master black belt?
The gap between what management thinks customers want and the process specifications.
To mentor/coach (and sometimes train) black belts.
Rapid improvement process.
To monitor a process when measurement by variables is used.

8. In a regression - what does R-square tell you?
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).
99.73%
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
A scatterplot.

9. For what is a p-chart used?
Fewer good units to sell - increased variable cost/unit.
No -- if it is not the same - it can only be worse!
To monitor a process when measurement by attribute is used.
68%

10. What is muda
Failure Modes and Effects Analysis
Waste.
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

11. Stratified defect check sheets
The gap between what customers expect and the service they receive.
Stratify a particular defect type according to logical criteria
Linearity - normality - homoscedasticity - independence.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

12. Which quality guru developed the concept of loss to society?
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 management thinks customers want and what customers really want.
Taguchi
X-bar-bar

13. Uses of regression - Control
Inventory = throughput x flow time.
To obtain a certain desirable outcome from the process
Sampling for SPC is done real time.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

14. Define conformance quality.
10 if Almost impossible to detect
F_alpha - df(tr) - df (error)
The degree to which a product meets pre-established standards.
Through producer/consumer negotiation.

15. What is a histogram?
Organize ideas into meaningful categories by recognizing their underlying similarity
50%
Speed - courtesy - competence - and ease of repair.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

16. Affinity Diagrams
Supplier - input - process - output - customer.
100%
The Japanese national quality award.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

17. Design of Experiments (DOE) approach
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The number of standard deviations some value is from the mean.
Not necessarily.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

18. If a Cp shows that a process is not capable - should you calculate Cpk?
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).
Walter A. Shewhart
Failure Modes and Effects Analysis
No -- if it is not the same - it can only be worse!

19. What happens to control limits on an SPC chart when sample size is increased?
Prevention and appraisal costs are balanced against internal and external failure.
Workers - machines - materials.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
They move closer to the center line.

20. Your production process meets customer specifications. Is your process in control?
Central Limit Theorem
Observed variation in response is caused by the input
Not necessarily.
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.

21. What do you do when a process is out of control?
No -- the variation also has to be random and "expected."
Look for the assignable cause of non-random variation.
Actual drawings - layouts - maps - etc which show where a defect occurs
Sampling for SPC is done real time.

22. When is Cpk used?
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).
Central Limit Theorem
To do a capability study for a non-centered process.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

23. If a three-stage process has 90% yields at each stage - what is the overall yield?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Kaoru Ishikawa.
To monitor a process when measurement by variables is used.
0.9^3 or 72.9%

24. Residual(eij)
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Producer risk.
Method developed by Ishikawa to graphically display the causes of any given problem

25. In a regression - what does the p value of F tell you?
Shows the temporal flow of activities in a project network.
The primary operating characteristics of a product.
Through producer/consumer negotiation.
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).

26. What is the formula for standard deviation?
To do a capability study for a non-centered 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
=sqrt(Σ(x-x-bar)^2)/(n-1))
Waste.

27. List two appraisal costs.
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).
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
False - because each machine will have different natural tolerances.

28. Manual Test for Nomality
False - because each machine will have different natural tolerances.
Not necessarily.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

29. Define aesthetic quality.
Attribute
A scatterplot.
Conformance to specifications.
Pleasing to the senses.

30. Failure Mode
Is the way in which the failure is manifested.
False - because each machine will have different natural tolerances.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
p-bar - the long-run percent defective.

31. Who developed the fishbone diagram?
Kaoru Ishikawa.
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
Defects Per Million Opportunities
To monitor a process when measurement by attribute is used.

32. What is Jidoka?
Method developed by Ishikawa to graphically display the causes of any given problem
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).
Controlling quality at the source.
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.

33. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
= yij - y(bar)i --> value minus sum of that treatment (of row)
Linearity - normality - homoscedasticity - independence.

34. What is process capability?
The ability of a process to consistently meet customer specifications.
Someone who is consistently against virtually everything.
A descending order-sorted bar chart with a cumulative percentage line.
= yij - y(bar)i --> value minus sum of that treatment (of row)

35. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Sampling for SPC is done real time.
Controlling quality at the source.
Speed - courtesy - competence - and ease of repair.
Is the consequence of the failure.

36. List two components of internal failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Critical to quality.
Is the way in which the failure is manifested.
Variable.

37. Defect check sheets
Different types of defects are listed (used for Pareto chart)
To monitor a process when measurement by variables is used.
Shifts - Trends - Repeating patterns - Correlation with known events
Fewer good units to sell - increased variable cost/unit.

38. Cause and Effect Diagrams
Upper control limit.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Method developed by Ishikawa to graphically display the causes of any given problem
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

39. Who is a process owner?
To mentor/coach (and sometimes train) black belts.
The US national quality award.
Kaoru Ishikawa.
The manager in charge of a process being improved in a Six Sigma project.

40. What is the center line of a p-chart?
Attribute
p-bar - the long-run percent defective.
It's good -- but it's still out of control!
Is the consequence of the failure.

41. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
The gap between what customers expect and the service they receive.
95%
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Prevention and appraisal costs are balanced against internal and external failure.

42. What is the center line of an X-bar chart?
X-bar-bar
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Deming.
A diagram that shows the relationships between activities in a project network.

43. What quality guru emphasizes management as a system?
The gap between specifications and how service is performed.
To monitor a process when measurement by attribute is used.
Deming.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

44. Effect ranking (Severity of the Defect)
10 for Hazardous without warning 1 for none
Someone who is consistently against virtually everything.
Financial - customer - internal process - innovation and learning.
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

45. In the Service Quality Gap Model - what is Gap 3?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
10 for Hazardous without warning 1 for none
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:
The gap between specifications and how service is performed.

46. What does Crosby say about benchmarking?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
If the Response vs. Levels graph if the response lines are not parallel (crossing)
= yij - y(bar)i --> value minus sum of that treatment (of row)
Lower control limit.

47. Process occurance ranking
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Technical quality is the "what" of the service; functional quality is the "how."
No -- only if the process is also capable.
Fishbone - cause-and-effect diagram.

48. What is FMEA?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Fitness for use.
Failure Modes and Effects Analysis
Mean time to failure.

49. 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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50. What is a network diagram?
68%
Variable.
A diagram that shows the relationships between activities in a project network.
Critical to quality.