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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 spaghetti diagram?
To be a member of a Six Sigma project team.
5%
A tool that shows the physical flows through a space.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

2. What is Value Stream Mapping?
A tool that shows where there is waste in a process.
Rapid improvement process.
Assigns scores to weighted criteria for each project under consideration.
Because the mean and standard deviation are independent of each other.

3. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Mean time to failure.
Outside.
Lean (or JIT).

4. 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
Conformance to specifications.
Look for the assignable cause of non-random variation.
To be a member of a Six Sigma project team.

5. If a Cp shows that a process is not capable - should you calculate Cpk?
Supplier - input - process - output - customer.
No -- if it is not the same - it can only be worse!
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

6. One factor at a time (OFAT)
Can't tell without a Range chart.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Hold all input variables constant except one. Observe the response as you vary the single input.
To do a capability study for a non-centered process.

7. Define aesthetic quality.
Defects Per Million Opportunities
The gap between what is promised and what is delivered.
The gap between specifications and how service is performed.
Pleasing to the senses.

8. How does Juran define quality?
To obtain a certain desirable outcome from the process
Variable.
100%
Fitness for use.

9. What is an affinity diagram?
Attribute.
To obtain a certain desirable outcome from the process
They move closer to the center line.
A brainstorming tool that shows the connections between ideas.

10. ANOVA

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11. Detection Criteria Ranking
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
10 if Almost impossible to detect
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
95%

12. What is DMADV?
Define - measure - analyze - design - verify.
Brand image.
Lower skill requirements - faster - less chance for error.
Defects Per Million Opportunities

13. In the Service Quality Gap Model - what is Gap 1?
F_alpha - df(tr) - df (error)
The gap between what management thinks customers want and what customers really want.
To mentor/coach (and sometimes train) black belts.
Observed variation in response is caused by the input

14. Explain the difference between technical and functional service quality.
10 if Almost impossible to detect
Represents the behavior of a process
Technical quality is the "what" of the service; functional quality is the "how."
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

15. 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
Fishbone - cause-and-effect diagram.
Lean (or JIT).
No -- only if the process is also capable.

16. When yields decrease - what are the two effects on contribution?
Fewer good units to sell - increased variable cost/unit.
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
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Method developed by Ishikawa to graphically display the causes of any given problem

17. If you have calculated a Cpk - should you also calculate a Cp?
The manager in charge of a process being improved in a Six Sigma project.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Can't tell without a Range chart.
The target number of standard deviations from the mean for specifications.

18. What is Little's Law?
Inventory = throughput x flow time.
The manager in charge of a process being improved in a Six Sigma project.
Consumer risk.
Fractional factorial designs (orthogonal arrays)

19. What percentage of a normal distribution lies above the mean?
Defects Per Million Opportunities
Fitness for use.
50%
Define - measure - analyze - design - verify.

20. Which type of SPC measurement is more precise - variable or attribute?
Variable.
The cycle time required to meet demand.
A tool that shows the physical flows through a space.
False - because each machine will have different natural tolerances.

21. Non-random patterns (Run Charts)
A diagram that shows the relationships between activities in a project network.
p-bar - the long-run percent defective.
Brand image.
Shifts - Trends - Repeating patterns - Correlation with known events

22. What graphical tool is used to show the relationship between two numerical variables?
A scatterplot.
Inventory = throughput x flow time.
Fitness for use.
3.4 (assuming 1.5 sigma shift in the mean)

23. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Concluding there has not been an effect/change when there has.
No -- the variation also has to be random and "expected."
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Attribute

24. Uses of regression
68%
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
To mentor/coach (and sometimes train) black belts.

25. What is Type II Error?
Concluding there has not been an effect/change when there has.
Can't tell without a Range chart.
Because the mean and standard deviation are independent of each other.
Workers - machines - materials.

26. What does the abbreviation LCL stand for?
Sort - Set in Order - Shine - Standardize - Sustain
Lower control limit.
Controlling quality at the source.
Before production starts

27. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Define - measure - analyze - improve - control.
Initiated before or at design concept finalization
68%
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

28. In a regression - what does the coefficient of the intercept tell you
Shifts - Trends - Repeating patterns - Correlation with known events
A brainstorming tool that shows the connections between ideas.
What the value of the dependent variable is when the independent variable is zero.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

29. Does it ever make sense to accept a job when a process is incapable?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
The target number of standard deviations from the mean for specifications.
The ability of a process to consistently meet customer specifications.
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

30. What is a dashboard?
A tool that shows performance along key dimensions all at once.
Technical quality is the "what" of the service; functional quality is the "how."
Outside.
Failure Modes and Effects Analysis

31. In a regression - what does the p value of F tell you?
Variable.
The gap between what management thinks customers want and what customers really want.
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).

32. F value
It's good -- but it's still out of control!
F_alpha - df(tr) - df (error)
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
If the Response vs. Levels graph if the response lines are not parallel (crossing)

33. FMEA
It looks to minimize the probability of a failure - or to minimize its effects
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).
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."

34. In a regression - what does the standard error of the estimate tell you?
Attribute.
The gap between what customers expect and the service they receive.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

35. What type of risk is associated with Type 1 Error?
Conformance to specifications.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Producer risk.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

36. What is a Pareto chart?
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).
A time series plot.
Lean is waste reduction - Six Sigma is variation reduction.
A descending order-sorted bar chart with a cumulative percentage line.

37. What are the four categories of costs in Juran's framework?
F_alpha - df(tr) - df (error)
Prevention - appraisal - internal failure - external failure.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Outside.

38. 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?
5%
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
False - because each machine will have different natural tolerances.
Central Limit Theorem

39. Define serviceability.
Failure Modes and Effects Analysis
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Is what induces the failure
Speed - courtesy - competence - and ease of repair.

40. What is Kaizen?
Concluding there has not been an effect/change when there has.
Controlling quality at the source.
3.4 (assuming 1.5 sigma shift in the mean)
Rapid improvement process.

41. To what does the Six in Six Sigma relate?
Mean time to failure.
Financial - customer - internal process - innovation and learning.
The target number of standard deviations from the mean for specifications.
To mentor/coach (and sometimes train) black belts.

42. Defect location check sheets
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 manage the Six Sigma project.
Lower skill requirements - faster - less chance for error.
Actual drawings - layouts - maps - etc which show where a defect occurs

43. What is Type 1 Error?
Concluding there has been an effect/change when there has not.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
A tool that shows the physical flows through a space.
Is the consequence of the failure.

44. Definition of Interaction
Is the consequence of the failure.
A descending order-sorted bar chart with a cumulative percentage line.
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
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

45. Define yield.
A scatterplot.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Studying firms with the best performance in a particular area.
The ratio of outputs to inputs; 1-scrap.

46. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
Sampling for SPC is done real time.
Large enough to find two of the attribute - on average.
Is the way in which the failure is manifested.

47. Define conformance quality.
X-bar-bar
A time series plot.
Lower control limit.
The degree to which a product meets pre-established standards.

48. Process check sheets
Used to create frequency distribution tally sheets
A descending order-sorted bar chart with a cumulative percentage line.
Because the mean and standard deviation are independent of each other.
A tool that shows where there is waste in a process.

49. List two appraisal costs.
Scrap - rework - retest - downtime - yield losses - disposition costs.
p-bar - the long-run percent defective.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
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.

50. Regression Analysis
3.4 (assuming 1.5 sigma shift in the mean)
Shifts - Trends - Repeating patterns - Correlation with known events
Someone who is consistently against virtually everything.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)