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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. Who is a process owner?
3.4 (assuming 1.5 sigma shift in the mean)
The manager in charge of a process being improved in a Six Sigma project.
Failure Modes and Effects Analysis
Prevention and appraisal costs are balanced against internal and external failure.

2. Define conformance quality.
Financial - customer - internal process - innovation and learning.
p-bar - the long-run percent defective.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The degree to which a product meets pre-established standards.

3. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Someone who is consistently against virtually everything.
The target number of standard deviations from the mean for specifications.
Attribute
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:

4. Define aesthetic quality.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Pleasing to the senses.
The gap between what is promised and what is delivered.
Look for the assignable cause of non-random variation.

5. What is the role of a master black belt?
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).
Kaoru Ishikawa.
95%
To mentor/coach (and sometimes train) black belts.

6. What are the Five Dimensions of Service Quality?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Technical quality is the "what" of the service; functional quality is the "how."
0.9^3 or 72.9%
Outside.

7. Uses of regression - Control
The gap between what customers expect and the service they receive.
0.9^3 or 72.9%
To obtain a certain desirable outcome from the process
Before production starts

8. Define perceived quality (Garvin's framework).
Shows the temporal flow of activities in a project network.
Brand image.
Shifts - Trends - Repeating patterns - Correlation with known events
The US national quality award.

9. What size should samples be for attribute SPC?
Represents the behavior of a process
Pleasing to the senses.
Large enough to find two of the attribute - on average.
A brainstorming tool that shows the connections between ideas.

10. List two appraisal costs.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
A time series plot.
Mean time to replacement.

11. Residual(eij)
= yij - y(bar)i --> value minus sum of that treatment (of row)
The gap between what management thinks customers want and the process specifications.
Through producer/consumer negotiation.
Variable.

12. What is the difference between the way sampling is done for SPC and for acceptance sampling?
The degree to which a product meets pre-established standards.
The primary operating characteristics of a product.
Sampling for SPC is done real time.
The gap between specifications and how service is performed.

13. What is a network diagram?
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
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A diagram that shows the relationships between activities in a project network.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

14. What do you do when a process is out of control?
Look for the assignable cause of non-random variation.
The House of Quality.
It's good -- but it's still out of control!
Speed - courtesy - competence - and ease of repair.

15. What is the center line of a p-chart?
p-bar - the long-run percent defective.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Speed - courtesy - competence - and ease of repair.
X-bar-bar

16. What is Little's Law?
QFD
Inventory = throughput x flow time.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Blame.

17. Name the structure associated with Quality Function Deployment.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The ratio of outputs to inputs; 1-scrap.
Sampling for SPC is done real time.
The House of Quality.

18. Process occurance ranking
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The gap between what is promised and what is delivered.
Variable.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

19. Define product reliability.
Prevention and appraisal costs are balanced against internal and external failure.
To mentor/coach (and sometimes train) black belts.
Mean time to failure.
Controlling quality at the source.

20. TWO-DIMENTIONAL SCATTER PLOT
The US national quality award.
Is the way in which the failure is manifested.
Shows the temporal flow of activities in a project network.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

21. The Test Statistic (TS)
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
To monitor a process when measurement by attribute is used.
A random variable that summarizes the information from the sample(s).
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

22. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
95%
Hold all input variables constant except one. Observe the response as you vary the single input.
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
Deming.

23. What does DMAIC stand for?
Define - measure - analyze - improve - control.
Used to create frequency distribution tally sheets
The Japanese national quality award.
No -- the variation also has to be random and "expected."

24. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
The manager in charge of a process being improved in a Six Sigma project.
Observed variation in response is caused by the input
The secondary characteristics of a product; "bells and whistles."

25. If you have calculated a Cpk - should you also calculate a Cp?
=sqrt(Σ(x-x-bar)^2)/(n-1))
F_alpha - df(tr) - df (error)
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
10 if Almost impossible to detect

26. In the Service Quality Gap Model - what is Gap 1?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
The gap between what management thinks customers want and what customers really want.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
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

27. Define durability.
Mean time to replacement.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
The ability of a process to consistently meet customer specifications.
Fewer good units to sell - increased variable cost/unit.

28. List two components of internal failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
The ability of a process to consistently meet customer specifications.
Large enough to find two of the attribute - on average.
Workers - machines - materials.

29. ANOVA

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30. What does Crosby say about benchmarking?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
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.
The gap between specifications and how service is performed.
The gap between what management thinks customers want and what customers really want.

31. What is Type II Error?
Pleasing to the senses.
p-bar - the long-run percent defective.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Concluding there has not been an effect/change when there has.

32. What is the difference between Lean and Six Sigma?
Lean is waste reduction - Six Sigma is variation reduction.
Fewer good units to sell - increased variable cost/unit.
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).
The secondary characteristics of a product; "bells and whistles."

33. Which quality guru developed the concept of loss to society?
Look for the assignable cause of non-random variation.
The gap between what is promised and what is delivered.
Speed - courtesy - competence - and ease of repair.
Taguchi

34. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Hold all input variables constant except one. Observe the response as you vary the single input.
Lean (or JIT).
Critical to quality.

35. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Outside.
F_alpha - df(tr) - df (error)
An assertion or conjecture concerning one or more populations
A diagram that shows the relationships between activities in a project network.

36. In the Service Quality Gap Model - what is Gap 5?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
The gap between what customers expect and the service they receive.
The number of standard deviations some value is from the mean.

37. In a regression - what does R-square tell you?
Shows the temporal flow of activities in a project network.
Because the mean and standard deviation are independent of each other.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Taguchi

38. What quality tool formally incorporates the voice of the customer?
Different types of defects are listed (used for Pareto chart)
QFD
95%
Pleasing to the senses.

39. Histogram by Hand
Mean time to failure.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The cycle time required to meet demand.
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

40. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
To monitor a process when measurement by variables is used.
The target number of standard deviations from the mean for specifications.
Variable.
To be a member of a Six Sigma project team.

41. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
100%
Not necessarily.
Upper control limit.

42. What is the formula for the standard deviation of a proportion?
The gap between specifications and how service is performed.
Failure Modes and Effects Analysis
=sqrt((p*(1-p)/n)
A scatterplot.

43. What is Type 1 Error?
To obtain a certain desirable outcome from the process
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
Concluding there has been an effect/change when there has not.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

44. Affinity Diagrams
Blame.
Is the way in which the failure is manifested.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
= 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

45. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Organize ideas into meaningful categories by recognizing their underlying similarity
Define - measure - analyze - improve - control.
No -- the variation also has to be random and "expected."
Walter A. Shewhart

46. Define serviceability.
99.73%
An assertion or conjecture concerning one or more populations
Speed - courtesy - competence - and ease of repair.
Mean time to replacement.

47. What are the four categories of costs in Juran's framework?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Prevention - appraisal - internal failure - external failure.
Technical quality is the "what" of the service; functional quality is the "how."
Prevention and appraisal costs are balanced against internal and external failure.

48. In the Service Quality Gap Model - what is Gap 4?
Financial - customer - internal process - innovation and learning.
The gap between what is promised and what is delivered.
Different types of defects are listed (used for Pareto chart)
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

49. How are LQL and AQL determined in an acceptance sampling plan?
Controlling quality at the source.
Sampling for SPC is done real time.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Through producer/consumer negotiation.

50. If a three-stage process has 90% yields at each stage - what is the overall yield?
0.9^3 or 72.9%
Variable.
The House of Quality.
Mean time to replacement.