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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. Define yield.
68%
Attribute
The ratio of outputs to inputs; 1-scrap.
A tool that shows the physical flows through a space.

2. What is a Gantt chart?
Shows the temporal flow of activities in a project network.
Controlling quality at the source.
95%
Represents the behavior of a process

3. 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
A diagram that shows the relationships between activities in a project network.
Is the way in which the failure is manifested.
Speed - courtesy - competence - and ease of repair.

4. What does SIPOC stand for?
Supplier - input - process - output - customer.
Fractional factorial designs (orthogonal arrays)
QFD
The gap between what is promised and what is delivered.

5. Define features.
X-bar-bar
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
Fewer good units to sell - increased variable cost/unit.
The secondary characteristics of a product; "bells and whistles."

6. What is the role of a master black belt?
False - because each machine will have different natural tolerances.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
p-bar - the long-run percent defective.
To mentor/coach (and sometimes train) black belts.

7. What is written on the "spines" of a fishbone diagram?
The gap between what is promised and what is delivered.
Attribute
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
Causes that lead to a particular effect.

8. What type of risk is associated with Type 1 Error?
Can't tell without a Range chart.
Controlling quality at the source.
Workers - machines - materials.
Producer risk.

9. Define performance quality.
Lean is waste reduction - Six Sigma is variation reduction.
The primary operating characteristics of a product.
99.73%
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

10. Does it ever make sense to accept a job when a process is incapable?
p-bar - the long-run percent defective.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
A brainstorming tool that shows the connections between ideas.
Attribute.

11. Define conformance quality.
No -- if it is not the same - it can only be worse!
The degree to which a product meets pre-established standards.
Failure Modes and Effects Analysis
No -- only if the process is also capable.

12. What do you do when a process is out of control?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Represents the behavior of a process
Look for the assignable cause of non-random variation.
Lean (or JIT).

13. What are the four regression assumptions?
The cycle time required to meet demand.
No -- if it is not the same - it can only be worse!
Linearity - normality - homoscedasticity - independence.
No -- the variation also has to be random and "expected."

14. Defect location check sheets
Actual drawings - layouts - maps - etc which show where a defect occurs
Lean (or JIT).
Pleasing to the senses.
Not necessarily.

15. 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
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

16. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Prevention and appraisal costs are balanced against internal and external failure.
They move closer to the center line.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
99.73%

17. Histogram by Hand
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
Mean time to replacement.
Inventory = throughput x flow time.
Can't tell without a Range chart.

18. What is a network diagram?
Shows the temporal flow of activities in a project network.
A diagram that shows the relationships between activities in a project network.
Defects Per Million Opportunities
It's good -- but it's still out of control!

19. Process check sheets
Shifts - Trends - Repeating patterns - Correlation with known events
Lean is waste reduction - Six Sigma is variation reduction.
Taguchi
Used to create frequency distribution tally sheets

20. If you have calculated a Cpk - should you also calculate a Cp?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
The cycle time required to meet demand.
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).
Prevention and appraisal costs are balanced against internal and external failure.

21. List two components of external failure.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

22. What are the four perspectives of the Balanced Scorecard?
Outside.
Shows the temporal flow of activities in a project network.
Financial - customer - internal process - innovation and learning.
The ratio of outputs to inputs; 1-scrap.

23. A process is operating "in control." Does this mean the customer's requirements are met?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Critical to quality.
No -- only if the process is also capable.
Can't tell without a Range chart.

24. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Initiated before or at design concept finalization
Financial - customer - internal process - innovation and learning.
Outside.
X-bar-bar

25. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
Look for the assignable cause of non-random variation.
It looks to minimize the probability of a failure - or to minimize its effects
Taguchi

26. What does the abbreviation UCL stand for?
Upper control limit.
It looks to minimize the probability of a failure - or to minimize its effects
Represents the behavior of a process
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:

27. One factor at a time (OFAT)
Represents the behavior of a process
Prevention - appraisal - internal failure - external failure.
Observed variation in response is caused by the input
A diagram that shows the relationships between activities in a project network.

28. Define takt time.
10 if Almost impossible to detect
p-bar - the long-run percent defective.
The cycle time required to meet demand.
F_alpha - df(tr) - df (error)

29. When yields decrease - what are the two effects on contribution?
Variable.
Fewer good units to sell - increased variable cost/unit.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Scrap - rework - retest - downtime - yield losses - disposition costs.

30. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
68%
The gap between what management thinks customers want and the process specifications.
Is what induces the failure
Attribute

31. Advantages of DOE
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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:
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

32. Define perceived quality (Garvin's framework).
Brand image.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
To monitor a process when measurement by variables is used.
Linearity - normality - homoscedasticity - independence.

33. 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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34. Affinity Diagrams
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
No -- if it is not the same - it can only be worse!
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Attribute

35. Defect check sheets
Different types of defects are listed (used for Pareto chart)
The manager in charge of a process being improved in a Six Sigma project.
Define - measure - analyze - improve - control.
Prevention - appraisal - internal failure - external failure.

36. What is FMEA?
Failure Modes and Effects Analysis
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The gap between what customers expect and the service they receive.
Lower control limit.

37. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
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.
X-bar-bar
A scatterplot.

38. What is a Pareto chart?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
A time series plot.
Sampling for SPC is done real time.
A descending order-sorted bar chart with a cumulative percentage line.

39. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Outside.
It looks to minimize the probability of a failure - or to minimize its effects
Pleasing to the senses.

40. The Test Statistic (TS)
A random variable that summarizes the information from the sample(s).
Initiated before or at design concept finalization
Stratify a particular defect type according to logical criteria
Rapid improvement process.

41. What is Value Stream Mapping?
Concluding there has been an effect/change when there has not.
=sqrt((p*(1-p)/n)
0.9^3 or 72.9%
A tool that shows where there is waste in a process.

42. What is a Gage R&R?
Upper control limit.
68%
Consumer risk.
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).

43. What is DMADV?
Concluding there has been an effect/change when there has not.
The secondary characteristics of a product; "bells and whistles."
Blame.
Define - measure - analyze - design - verify.

44. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Mean time to replacement.
Prevention and appraisal costs are balanced against internal and external failure.
A brainstorming tool that shows the connections between ideas.
They move closer to the center line.

45. What is CTQ?
Critical to quality.
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 gap between what management thinks customers want and the process specifications.
Walter A. Shewhart

46. What is the center line of a p-chart?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Taguchi
Lower control limit.
p-bar - the long-run percent defective.

47. Simple Regression Analysis (one factor regression model)
The primary operating characteristics of a product.
To do a capability study for a non-centered process.
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).
= 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

48. List Garvin's eight dimensions of product quality.
Financial - customer - internal process - innovation and learning.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
10 if Almost impossible to detect

49. What quality guru emphasizes management as a system?
Variable.
Deming.
Shifts - Trends - Repeating patterns - Correlation with known events
Outside.

50. In the Service Quality Gap Model - what is Gap 5?
= yij - y(bar)i --> value minus sum of that treatment (of row)
To obtain a certain desirable outcome from the process
False - because each machine will have different natural tolerances.
The gap between what customers expect and the service they receive.