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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 dashboard?
Outside.
No -- if it is not the same - it can only be worse!
A tool that shows performance along key dimensions all at once.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

2. What is a histogram?
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.
The US national quality award.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

3. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Conformance to specifications.
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.
To mentor/coach (and sometimes train) black belts.
Rapid improvement process.

4. Statistical Hypothesis
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
An assertion or conjecture concerning one or more populations
Prevention and appraisal costs are balanced against internal and external failure.

5. What is Jidoka?
Controlling quality at the source.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Technical quality is the "what" of the service; functional quality is the "how."
The number of standard deviations some value is from the mean.

6. To what does the Six in Six Sigma relate?
The target number of standard deviations from the mean for specifications.
To manage the Six Sigma project.
The primary operating characteristics of a product.
Hold all input variables constant except one. Observe the response as you vary the single input.

7. What is a CAVE man?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Shows the temporal flow of activities in a project network.
Prevention - appraisal - internal failure - external failure.
Someone who is consistently against virtually everything.

8. Non-random patterns (Run Charts)
The House of Quality.
The ability of a process to consistently meet customer specifications.
Shifts - Trends - Repeating patterns - Correlation with known events
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

9. What is Type II Error?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Concluding there has not been an effect/change when there has.
What the value of the dependent variable is when the independent variable is zero.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

10. Uses of regression - Control
To obtain a certain desirable outcome from the process
Taguchi
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Mistake-proofing.

11. Does it ever make sense to accept a job when a process is incapable?
The gap between what customers expect and the service they receive.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Not necessarily.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

12. Name the structure associated with Quality Function Deployment.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
The House of Quality.
The target number of standard deviations from the mean for specifications.
Upper control limit.

13. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
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
Pleasing to the senses.
Concluding there has not been an effect/change when there has.

14. What is a run chart?
A time series plot.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Central Limit Theorem
An assertion or conjecture concerning one or more populations

15. What quality guru emphasizes management as a system?
It looks to minimize the probability of a failure - or to minimize its effects
Shifts - Trends - Repeating patterns - Correlation with known events
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Deming.

16. With Six Sigma capability - how many defects per million opportunities would you see?
Scrap - rework - retest - downtime - yield losses - disposition costs.
3.4 (assuming 1.5 sigma shift in the mean)
Mistake-proofing.
Sort - Set in Order - Shine - Standardize - Sustain

17. Affinity Diagrams
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Fitness for use.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

18. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Shows the temporal flow of activities in a project network.
No -- the variation also has to be random and "expected."
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).

19. 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?
False - because each machine will have different natural tolerances.
The ratio of outputs to inputs; 1-scrap.
The House of Quality.
Variable.

20. In a regression - what does the p value of F tell you?
Method developed by Ishikawa to graphically display the causes of any given problem
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The manager in charge of a process being improved in a Six Sigma project.
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).

21. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Sort - Set in Order - Shine - Standardize - Sustain
Central Limit Theorem
Walter A. Shewhart
99.73%

22. Disadvantages of DOE

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23. Defect check sheets
= 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
Producer risk.
Pleasing to the senses.
Different types of defects are listed (used for Pareto chart)

24. What does Crosby say about benchmarking?
= 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
It's good -- but it's still out of control!
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)

25. Test for constant variance
Organize ideas into meaningful categories by recognizing their underlying similarity
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.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
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

26. Define performance quality.
Can't tell without a Range chart.
The ratio of outputs to inputs; 1-scrap.
Lean (or JIT).
The primary operating characteristics of a product.

27. Risk Priority Number RPN
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
5%
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The primary operating characteristics of a product.

28. How does Juran define quality?
Technical quality is the "what" of the service; functional quality is the "how."
False - because each machine will have different natural tolerances.
Fitness for use.
3.4 (assuming 1.5 sigma shift in the mean)

29. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
The secondary characteristics of a product; "bells and whistles."
Workers - machines - materials.
Fishbone - cause-and-effect diagram.

30. Effect ranking (Severity of the Defect)
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
10 for Hazardous without warning 1 for none
The House of Quality.
Variable.

31. In Juran's Cost of Quality model - which categories of costs balance which other categories?
68%
Lower skill requirements - faster - less chance for error.
Conformance to specifications.
Prevention and appraisal costs are balanced against internal and external failure.

32. Taguchi's experimental designs are of this type.
Prevention and appraisal costs are balanced against internal and external failure.
A tool that shows performance along key dimensions all at once.
The target number of standard deviations from the mean for specifications.
Fractional factorial designs (orthogonal arrays)

33. What is the role of a master black belt?
To mentor/coach (and sometimes train) black belts.
To obtain a certain desirable outcome from the process
Studying firms with the best performance in a particular area.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

34. What does DMAIC stand for?
Waste.
Define - measure - analyze - improve - control.
Fishbone - cause-and-effect diagram.
F_alpha - df(tr) - df (error)

35. Advantages of DOE
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
Failure Modes and Effects Analysis
Stratify a particular defect type according to logical criteria
Linearity - normality - homoscedasticity - independence.

36. Process occurance ranking
99.73%
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
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

37. What quality tool formally incorporates the voice of the customer?
Defects Per Million Opportunities
Walter A. Shewhart
QFD
Scrap - rework - retest - downtime - yield losses - disposition costs.

38. In a regression - what does the standard error of the estimate tell you?
Attribute
Represents the behavior of a process
The gap between what management thinks customers want and what customers really want.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

39. Which quality guru developed the concept of loss to society?
The secondary characteristics of a product; "bells and whistles."
They move closer to the center line.
Controlling quality at the source.
Taguchi

40. What happens to control limits on an SPC chart when sample size is increased?
= yij - y(bar)i --> value minus sum of that treatment (of row)
Define - measure - analyze - improve - control.
What the value of the dependent variable is when the independent variable is zero.
They move closer to the center line.

41. What are the Five Dimensions of Service Quality?
Method developed by Ishikawa to graphically display the causes of any given problem
Central Limit Theorem
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Studying firms with the best performance in a particular area.

42. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Sampling for SPC is done real time.
Stratify a particular defect type according to logical criteria
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
A diagram that shows the relationships between activities in a project network.

43. If you have calculated a Cpk - should you also calculate a Cp?
Studying firms with the best performance in a particular area.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
No -- if it is not the same - it can only be worse!

44. What is a Gantt chart?
The primary operating characteristics of a product.
Is what induces the failure
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Shows the temporal flow of activities in a project network.

45. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Concluding there has been an effect/change when there has not.
Financial - customer - internal process - innovation and learning.
95%
Deming.

46. What are the four perspectives of the Balanced Scorecard?
Financial - customer - internal process - innovation and learning.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The manager in charge of a process being improved in a Six Sigma project.

47. For what is an x-bar chart used?
To monitor a process when measurement by variables is used.
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.
Lean (or JIT).
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

48. How are LQL and AQL determined in an acceptance sampling plan?
Through producer/consumer negotiation.
No -- the variation also has to be random and "expected."
The number of standard deviations some value is from the mean.
Is what induces the failure

49. Define durability.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Mean time to replacement.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
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

50. Histogram by Hand
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
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
50%
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.