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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. DFMEA
Initiated before or at design concept finalization
It's good -- but it's still out of control!
Mean time to failure.
Outside.

2. Define serviceability.
Speed - courtesy - competence - and ease of repair.
Before production starts
100%
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

3. Detection Criteria Ranking
10 if Almost impossible to detect
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Represents the behavior of a process
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

4. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Outside.
Define - measure - analyze - design - verify.
3.4 (assuming 1.5 sigma shift in the mean)

5. Does it ever make sense to accept a job when a process is incapable?
68%
Variable.
To obtain a certain desirable outcome from the process
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

6. Defect check sheets
The gap between what management thinks customers want and what customers really want.
Upper control limit.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Different types of defects are listed (used for Pareto chart)

7. What is DMADV?
p-bar - the long-run percent defective.
Define - measure - analyze - design - verify.
The cycle time required to meet demand.
Variable.

8. What happens to control limits on an SPC chart when sample size is increased?
Brand image.
They move closer to the center line.
Shifts - Trends - Repeating patterns - Correlation with known events
Prevention - appraisal - internal failure - external failure.

9. Disadvantages of DOE

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10. DOE
Rapid improvement process.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Sort - Set in Order - Shine - Standardize - Sustain

11. Who first studied randomness in industrial processes
Walter A. Shewhart
What the value of the dependent variable is when the independent variable is zero.
Causes that lead to a particular effect.
Defects Per Million Opportunities

12. In the Service Quality Gap Model - what is Gap 5?
A tool that shows performance along key dimensions all at once.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
The gap between what customers expect and the service they receive.
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).

13. Advantages of DOE
10 if Almost impossible to detect
Can't tell without a Range chart.
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
Attribute

14. 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?
Fishbone - cause-and-effect diagram.
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.
False - because each machine will have different natural tolerances.
Initiated before or at design concept finalization

15. What is Type II Error?
Through producer/consumer negotiation.
Consumer risk.
Defects Per Million Opportunities
Concluding there has not been an effect/change when there has.

16. What are two other names for an Ishikawa diagram?
Sort - Set in Order - Shine - Standardize - Sustain
Organize ideas into meaningful categories by recognizing their underlying similarity
Fishbone - cause-and-effect diagram.
A diagram that shows the relationships between activities in a project network.

17. Process occurance ranking
p-bar - the long-run percent defective.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
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 manager in charge of a process being improved in a Six Sigma project.

18. In the Service Quality Gap Model - what is Gap 2?
The gap between what management thinks customers want and the process specifications.
The number of standard deviations some value is from the mean.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Can't tell without a Range chart.

19. What is a Pareto chart?
A descending order-sorted bar chart with a cumulative percentage line.
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
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Look for the assignable cause of non-random variation.

20. What is a spaghetti diagram?
Fewer good units to sell - increased variable cost/unit.
A tool that shows the physical flows through a space.
Sort - Set in Order - Shine - Standardize - Sustain
A tool that shows performance along key dimensions all at once.

21. What type of risk is associated with Type II Error?
Consumer risk.
Mistake-proofing.
Is what induces the failure
Concluding there has been an effect/change when there has not.

22. Histogram by Hand
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Sort - Set in Order - Shine - Standardize - Sustain
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
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

23. Daniel Test
Speed - courtesy - competence - and ease of repair.
They move closer to the center line.
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:
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

24. Stratified defect check sheets
=sqrt((p*(1-p)/n)
Through producer/consumer negotiation.
Not necessarily.
Stratify a particular defect type according to logical criteria

25. Creating a Run Chart
What the value of the dependent variable is when the independent variable is zero.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The House of Quality.
Fishbone - cause-and-effect diagram.

26. Definition of Interaction
Represents the behavior of a process
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
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
p-bar - the long-run percent defective.

27. What is the role of a master black belt?
Fewer good units to sell - increased variable cost/unit.
A tool that shows where there is waste in a process.
The gap between what is promised and what is delivered.
To mentor/coach (and sometimes train) black belts.

28. Effect ranking (Severity of the Defect)
10 for Hazardous without warning 1 for none
A diagram that shows the relationships between activities in a project network.
Conformance to specifications.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

29. What is the role of a green belt?
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
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
To be a member of a Six Sigma project team.
=sqrt(Σ(x-x-bar)^2)/(n-1))

30. A process is operating "in control." Does this mean the customer's requirements are met?
Walter A. Shewhart
No -- only if the process is also capable.
Pleasing to the senses.
Look for the assignable cause of non-random variation.

31. What is Kaizen?
Rapid improvement process.
The gap between specifications and how service is performed.
Organize ideas into meaningful categories by recognizing their underlying similarity
A tool that shows where there is waste in a process.

32. What quality tool formally incorporates the voice of the customer?
QFD
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Linearity - normality - homoscedasticity - independence.
Define - measure - analyze - design - verify.

33. In a Z table - what is Z?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
A tool that shows performance along key dimensions all at once.
The number of standard deviations some value is from the mean.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

34. Presence of interaction effect
Mean time to replacement.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Walter A. Shewhart

35. What are the Five Dimensions of Service Quality?
Organize ideas into meaningful categories by recognizing their underlying similarity
Attribute.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Conformance to specifications.

36. Who is a process owner?
Consumer risk.
=sqrt(Σ(x-x-bar)^2)/(n-1))
The manager in charge of a process being improved in a Six Sigma project.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

37. What is the Deming Prize?
The Japanese national quality award.
The primary operating characteristics of a product.
95%
0.9^3 or 72.9%

38. Based on what principal can we use the normal distribution assumptions for SPC?
Controlling quality at the source.
A tool that shows where there is waste in a process.
A scatterplot.
Central Limit Theorem

39. Taguchi's experimental designs are of this type.
Assigns scores to weighted criteria for each project under consideration.
Fractional factorial designs (orthogonal arrays)
The gap between what management thinks customers want and what customers really want.
Lower control limit.

40. In a regression - what does the p value of F 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).
Define - measure - analyze - design - verify.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
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

41. What is the 5S model?
A diagram that shows the relationships between activities in a project network.
A scatterplot.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Observed variation in response is caused by the input

42. What does DMAIC stand for?
The gap between what customers expect and the service they receive.
Define - measure - analyze - improve - control.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
50%

43. For what is a p-chart used?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Linearity - normality - homoscedasticity - independence.
To monitor a process when measurement by attribute is used.

44. FMEA
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
It looks to minimize the probability of a failure - or to minimize its effects
The number of standard deviations some value is from the mean.
To be a member of a Six Sigma project team.

45. Define durability.
Mean time to replacement.
Method developed by Ishikawa to graphically display the causes of any given problem
QFD
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

46. In the Service Quality Gap Model - what is Gap 4?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Shows the temporal flow of activities in a project network.
The cycle time required to meet demand.
The gap between what is promised and what is delivered.

47. List two appraisal costs.
Shifts - Trends - Repeating patterns - Correlation with known events
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
To obtain a certain desirable outcome from the process
It's good -- but it's still out of control!

48. What is the center line of an X-bar chart?
Technical quality is the "what" of the service; functional quality is the "how."
Sampling for SPC is done real time.
X-bar-bar
p-bar - the long-run percent defective.

49. What is the Baldrige Award?
The US national quality award.
Fishbone - cause-and-effect diagram.
A scatterplot.
10 if Almost impossible to detect

50. What is the difference between Lean and Six Sigma?
Lean is waste reduction - Six Sigma is variation reduction.
The secondary characteristics of a product; "bells and whistles."
Technical quality is the "what" of the service; functional quality is the "how."
The cycle time required to meet demand.