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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. Complete this quality phrase: 'Fix the process - not the _____.'
A descending order-sorted bar chart with a cumulative percentage line.
Blame.
Scrap - rework - retest - downtime - yield losses - disposition costs.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

2. The Test Statistic (TS)
Upper control limit.
3.4 (assuming 1.5 sigma shift in the mean)
Before production starts
A random variable that summarizes the information from the sample(s).

3. What is process capability?
p-bar - the long-run percent defective.
The ability of a process to consistently meet customer specifications.
68%
Represents the behavior of a process

4. What are two other names for an Ishikawa diagram?
It looks to minimize the probability of a failure - or to minimize its effects
Fishbone - cause-and-effect diagram.
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:
Concluding there has not been an effect/change when there has.

5. Define takt time.
The number of standard deviations some value is from the mean.
5%
A tool that shows where there is waste in a process.
The cycle time required to meet demand.

6. DFMEA
Shows the temporal flow of activities in a project network.
Initiated before or at design concept finalization
They move closer to the center line.
=sqrt(Σ(x-x-bar)^2)/(n-1))

7. In the Service Quality Gap Model - what is Gap 3?
Waste.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
To monitor a process when measurement by variables is used.
The gap between specifications and how service is performed.

8. Residual(eij)
Shows the temporal flow of activities in a project network.
A tool that shows the physical flows through a space.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Method developed by Ishikawa to graphically display the causes of any given problem

9. ANOVA

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10. Uses of regression - Control
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
To obtain a certain desirable outcome from the process
To monitor a process when measurement by attribute is used.
To manage the Six Sigma project.

11. Affinity Diagrams
Initiated before or at design concept finalization
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Studying firms with the best performance in a particular area.
Organize ideas into meaningful categories by recognizing their underlying similarity

12. TWO-DIMENTIONAL SCATTER PLOT
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Stratify a particular defect type according to logical criteria
Producer risk.
Conformance to specifications.

13. Creating a Run Chart
Look for the assignable cause of non-random variation.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Kaoru Ishikawa.
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. A process is operating "in control." Does this mean the customer's requirements are met?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Shifts - Trends - Repeating patterns - Correlation with known events
No -- only if the process is also capable.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

15. What does SIPOC stand for?
Lower skill requirements - faster - less chance for error.
Supplier - input - process - output - customer.
3.4 (assuming 1.5 sigma shift in the mean)
Central Limit Theorem

16. With Six Sigma capability - how many defects per million opportunities would you see?
Fitness for use.
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:
3.4 (assuming 1.5 sigma shift in the mean)
=sqrt(Σ(x-x-bar)^2)/(n-1))

17. List two components of prevention cost.
To monitor a process when measurement by variables is used.
The gap between what is promised and what is delivered.
Fewer good units to sell - increased variable cost/unit.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

18. Based on what principal can we use the normal distribution assumptions for SPC?
Mistake-proofing.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Central Limit Theorem
Pleasing to the senses.

19. Define product reliability.
Conformance to specifications.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Mean time to failure.

20. Simple Regression Analysis (one factor regression model)
The House of Quality.
To monitor a process when measurement by variables is used.
= 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
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.

21. What is the role of a green belt?
No -- the variation also has to be random and "expected."
To be a member of a Six Sigma project team.
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
= 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

22. What happens to control limits on an SPC chart when sample size is increased?
10 if Almost impossible to detect
They move closer to the center line.
A tool that shows where there is waste in a process.
Mean time to replacement.

23. If a Cp shows that a process is not capable - should you calculate Cpk?
= yij - y(bar)i --> value minus sum of that treatment (of row)
No -- if it is not the same - it can only be worse!
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.
Method developed by Ishikawa to graphically display the causes of any given problem

24. Why do you need two control charts for variables SPC?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
10 for Hazardous without warning 1 for none
Because the mean and standard deviation are independent of each other.
=sqrt(Σ(x-x-bar)^2)/(n-1))

25. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
Taguchi
50%
To manage the Six Sigma project.

26. In a regression - what does the p value of F tell you?
Outside.
Assigns scores to weighted criteria for each project under consideration.
A random variable that summarizes the information from the sample(s).
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).

27. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
The secondary characteristics of a product; "bells and whistles."
Lower skill requirements - faster - less chance for error.
100%
Central Limit Theorem

28. List two components of internal failure.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Scrap - rework - retest - downtime - yield losses - disposition costs.
A tool that shows performance along key dimensions all at once.
Mean time to failure.

29. Design of Experiments (DOE) approach
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Initiated before or at design concept finalization
The gap between what management thinks customers want and what customers really want.
To manage the Six Sigma project.

30. Histogram by Hand
A brainstorming tool that shows the connections between ideas.
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
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Sampling for SPC is done real time.

31. What is the Baldrige Award?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
QFD
Define - measure - analyze - improve - control.
The US national quality award.

32. F value
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Because the mean and standard deviation are independent of each other.
F_alpha - df(tr) - df (error)
Fishbone - cause-and-effect diagram.

33. What percentage of a normal distribution lies above the mean?
Variable.
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).
Shifts - Trends - Repeating patterns - Correlation with known events
50%

34. What is the role of a black belt?
Used to create frequency distribution tally sheets
To manage the Six Sigma project.
Fractional factorial designs (orthogonal arrays)
Lean (or JIT).

35. In a regression - what does the standard error of the estimate tell you?
They move closer to the center line.
A tool that shows the physical flows through a space.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Technical quality is the "what" of the service; functional quality is the "how."

36. Risk Priority Number RPN
Is the way in which the failure is manifested.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
QFD
Define - measure - analyze - improve - control.

37. What is Type II Error?
Initiated before or at design concept finalization
Concluding there has not been an effect/change when there has.
To manage the Six Sigma project.
100%

38. Define aesthetic quality.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Define - measure - analyze - improve - control.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Pleasing to the senses.

39. What is DMADV?
Organize ideas into meaningful categories by recognizing their underlying similarity
Define - measure - analyze - design - verify.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
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).

40. What type of risk is associated with Type II Error?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Pleasing to the senses.
Consumer risk.

41. What quality guru emphasizes management as a system?
10 for Hazardous without warning 1 for none
Fewer good units to sell - increased variable cost/unit.
Deming.
Sampling for SPC is done real time.

42. In the Service Quality Gap Model - what is Gap 4?
The gap between specifications and how service is performed.
A tool that shows the physical flows through a space.
The gap between what is promised and what is delivered.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

43. What is a Gantt chart?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Shows the temporal flow of activities in a project network.
Because the mean and standard deviation are independent of each other.
Waste.

44. Define durability.
Method developed by Ishikawa to graphically display the causes of any given problem
Mean time to replacement.
Waste.
Lower control limit.

45. What is written on the "spines" of a fishbone diagram?
Workers - machines - materials.
Outside.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Causes that lead to a particular effect.

46. Your production process meets customer specifications. Is your process in control?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
No -- the variation also has to be random and "expected."
Prevention - appraisal - internal failure - external failure.
Not necessarily.

47. What are the Five Dimensions of Service Quality?
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
Reliability - Assurance - Responsiveness - Tangibles - Empathy
They move closer to the center line.
Define - measure - analyze - design - verify.

48. What is the Deming Prize?
The Japanese national quality award.
Variable.
Concluding there has not been an effect/change when there has.
p-bar - the long-run percent defective.

49. Regression
Represents the behavior of a process
Kaoru Ishikawa.
10 for Hazardous without warning 1 for none
A descending order-sorted bar chart with a cumulative percentage line.

50. When is Cpk used?
False - because each machine will have different natural tolerances.
Central Limit Theorem
Fishbone - cause-and-effect diagram.
To do a capability study for a non-centered process.