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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.
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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. List two appraisal costs.
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
Kaoru Ishikawa.
Lean is waste reduction - Six Sigma is variation reduction.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

2. What type of risk is associated with Type 1 Error?
3.4 (assuming 1.5 sigma shift in the mean)
Variable.
Producer risk.
Not necessarily.

3. Name the structure associated with Quality Function Deployment.
The gap between what customers expect and the service they receive.
Lean is waste reduction - Six Sigma is variation reduction.
The House of Quality.
Initiated before or at design concept finalization

4. In the Service Quality Gap Model - what is Gap 2?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The gap between what management thinks customers want and the process specifications.
Mistake-proofing.
The target number of standard deviations from the mean for specifications.

5. One factor at a time (OFAT)
Observed variation in response is caused by the input
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Stratify a particular defect type according to logical criteria
The target number of standard deviations from the mean for specifications.

6. Process occurance ranking
Failure Modes and Effects Analysis
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Assigns scores to weighted criteria for each project under consideration.
The degree to which a product meets pre-established standards.

7. The Test Statistic (TS)
A random variable that summarizes the information from the sample(s).
A descending order-sorted bar chart with a cumulative percentage line.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Is what induces the failure

8. Define takt time.
The cycle time required to meet demand.
Financial - customer - internal process - innovation and learning.
Rapid improvement process.
What the value of the dependent variable is when the independent variable is zero.

9. What does a project prioritization matrix do?
Concluding there has not been an effect/change when there has.
Assigns scores to weighted criteria for each project under consideration.
A diagram that shows the relationships between activities in a project network.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

10. Explain the difference between technical and functional service quality.
Actual drawings - layouts - maps - etc which show where a defect occurs
Variable.
Technical quality is the "what" of the service; functional quality is the "how."
Not necessarily.

11. What is a dashboard?
=sqrt((p*(1-p)/n)
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.
Lower control limit.
A tool that shows performance along key dimensions all at once.

12. Defect check sheets
The target number of standard deviations from the mean for specifications.
To obtain a certain desirable outcome from the process
Different types of defects are listed (used for Pareto chart)
95%

13. If you have calculated a Cpk - should you also calculate a Cp?
No -- the variation also has to be random and "expected."
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
An assertion or conjecture concerning one or more populations
A descending order-sorted bar chart with a cumulative percentage line.

14. Histogram by Hand
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Kaoru Ishikawa.
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
A time series plot.

15. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
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
The House of Quality.
Lower skill requirements - faster - less chance for error.
A tool that shows the physical flows through a space.

16. Who is a process owner?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Different types of defects are listed (used for Pareto chart)
The manager in charge of a process being improved in a Six Sigma project.
Someone who is consistently against virtually everything.

17. What size should samples be for attribute SPC?
Scrap - rework - retest - downtime - yield losses - disposition costs.
Different types of defects are listed (used for Pareto 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
Large enough to find two of the attribute - on average.

18. Regression
Shifts - Trends - Repeating patterns - Correlation with known events
Initiated before or at design concept finalization
The gap between what management thinks customers want and what customers really want.
Represents the behavior of a process

19. Detection Criteria Ranking
95%
50%
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).
10 if Almost impossible to detect

20. What is a histogram?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
What the value of the dependent variable is when the independent variable is zero.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
No -- only if the process is also capable.

21. What is a CAVE man?
Shows the temporal flow of activities in a project network.
68%
Someone who is consistently against virtually everything.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

22. For what is an x-bar chart used?
To monitor a process when measurement by variables is used.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
10 if Almost impossible to detect
Failure Modes and Effects Analysis

23. F value
=sqrt((p*(1-p)/n)
F_alpha - df(tr) - df (error)
Speed - courtesy - competence - and ease of repair.
Define - measure - analyze - design - verify.

24. Disadvantages of DOE

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25. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Conformance to specifications.
95%
Used to create frequency distribution tally sheets

26. Define durability.
The secondary characteristics of a product; "bells and whistles."
Mean time to replacement.
Linearity - normality - homoscedasticity - independence.
Different types of defects are listed (used for Pareto chart)

27. What is the role of a green belt?
Large enough to find two of the attribute - on average.
Concluding there has been an effect/change when there has not.
To be a member of a Six Sigma project team.
Before production starts

28. PFMEA
A tool that shows performance along key dimensions all at once.
Before production starts
Is the way in which the failure is manifested.
A descending order-sorted bar chart with a cumulative percentage line.

29. List Garvin's eight dimensions of product quality.
Look for the assignable cause of non-random variation.
The gap between specifications and how service is performed.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
They move closer to the center line.

30. What are the 5 Ss?
The primary operating characteristics of a product.
Fitness for use.
Sort - Set in Order - Shine - Standardize - Sustain
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

31. TWO-DIMENTIONAL SCATTER PLOT
Define - measure - analyze - improve - control.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
5%
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

32. What does Crosby say about benchmarking?
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
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.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

33. A process is operating "in control." Does this mean the customer's requirements are met?
Attribute
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
No -- only if the process is also capable.
Linearity - normality - homoscedasticity - independence.

34. Manual Test for Nomality
Shows the temporal flow of 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
Actual drawings - layouts - maps - etc which show where a defect occurs
Look for the assignable cause of non-random variation.

35. What type of risk is associated with Type II Error?
Method developed by Ishikawa to graphically display the causes of any given problem
99.73%
Conformance to specifications.
Consumer risk.

36. In a regression - what does the p value of F tell you?
The gap between what management thinks customers want and the process specifications.
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).
Lean is waste reduction - Six Sigma is variation reduction.
The secondary characteristics of a product; "bells and whistles."

37. Who first studied randomness in industrial processes
Walter A. Shewhart
No -- only if the process is also capable.
To monitor a process when measurement by attribute is used.
A diagram that shows the relationships between activities in a project network.

38. Your production process meets customer specifications. Is your process in control?
Before production starts
Not necessarily.
No -- the variation also has to be random and "expected."
Controlling quality at the source.

39. What is the role of a black belt?
Is the way in which the failure is manifested.
Blame.
Attribute.
To manage the Six Sigma project.

40. Creating a Run Chart
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Waste.
The gap between what customers expect and the service they receive.
Large enough to find two of the attribute - on average.

41. What percentage of a normal distribution lies above the mean?
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
To manage the Six Sigma project.
50%
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

42. In a regression - what does R-square tell you?
They move closer to the center line.
Sampling for SPC is done real time.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

43. Define performance quality.
10 for Hazardous without warning 1 for none
The primary operating characteristics of a product.
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
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

44. Advantages of DOE
They move closer to the center line.
A tool that shows performance along key dimensions all at once.
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
A random variable that summarizes the information from the sample(s).

45. What are the three main categories of assignable cause?
Lean is waste reduction - Six Sigma is variation reduction.
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
50%
Workers - machines - materials.

46. With Six Sigma capability - how many defects per million opportunities would you see?
Is what induces the failure
3.4 (assuming 1.5 sigma shift in the mean)
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

47. FMEA
p-bar - the long-run percent defective.
It looks to minimize the probability of a failure - or to minimize its effects
Attribute
Workers - machines - materials.

48. Who developed the fishbone diagram?
Prevention and appraisal costs are balanced against internal and external failure.
Kaoru Ishikawa.
Waste.
The gap between what is promised and what is delivered.

49. ANOVA

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50. What is the center line of a p-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
p-bar - the long-run percent defective.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.