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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. Process check sheets
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
It's good -- but it's still out of control!
A brainstorming tool that shows the connections between ideas.
Used to create frequency distribution tally sheets

2. What is written on the "spines" of a fishbone diagram?
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
Causes that lead to a particular effect.
To obtain a certain desirable outcome from the process
Attribute.

3. Who developed the fishbone diagram?
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
Kaoru Ishikawa.
Shows the temporal flow of activities in a project network.
To mentor/coach (and sometimes train) black belts.

4. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Variable.
0.9^3 or 72.9%
The gap between what management thinks customers want and the process specifications.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

5. Detection Criteria Ranking
Conformance to specifications.
Through producer/consumer negotiation.
Mean time to replacement.
10 if Almost impossible to detect

6. Defect location check sheets
Actual drawings - layouts - maps - etc which show where a defect occurs
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
The ratio of outputs to inputs; 1-scrap.
68%

7. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Shifts - Trends - Repeating patterns - Correlation with known events
To do a capability study for a non-centered process.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
5%

8. Taguchi's experimental designs are of this type.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
To manage the Six Sigma project.
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
Fractional factorial designs (orthogonal arrays)

9. What are two other names for an Ishikawa diagram?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
=sqrt((p*(1-p)/n)
Fishbone - cause-and-effect diagram.
The US national quality award.

10. Design of Experiments (DOE) approach
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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
Taguchi
Workers - machines - materials.

11. Regression Analysis
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
A tool that shows where there is waste in a process.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

12. What is process capability?
Is what induces the failure
The number of standard deviations some value is from the mean.
The ability of a process to consistently meet customer specifications.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

13. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
A descending order-sorted bar chart with a cumulative percentage line.
A brainstorming tool that shows the connections between ideas.
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:

14. What graphical tool is used to show the relationship between two numerical variables?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
10 if Almost impossible to detect
Attribute
A scatterplot.

15. What are the Five Dimensions of Service Quality?
Deming.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
QFD
Controlling quality at the source.

16. List two components of prevention cost.
To manage the Six Sigma project.
No -- if it is not the same - it can only be worse!
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Walter A. Shewhart

17. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Define - measure - analyze - improve - control.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Lean (or JIT).
Different types of defects are listed (used for Pareto chart)

18. In a regression - what does R-square tell you?
A time series plot.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

19. In a regression - what does the standard error of the estimate tell you?
= yij - y(bar)i --> value minus sum of that treatment (of row)
Mistake-proofing.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
What the value of the dependent variable is when the independent variable is zero.

20. Histogram by Hand
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
Upper control limit.
The target number of standard deviations from the mean for specifications.
A tool that shows performance along key dimensions all at once.

21. What is FMEA?
Failure Modes and Effects Analysis
Concluding there has been an effect/change when there has not.
A brainstorming tool that shows the connections between ideas.
Can't tell without a Range chart.

22. What is a CAVE man?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
= 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
X-bar-bar
Someone who is consistently against virtually everything.

23. What is Type II Error?
Is what induces the failure
Controlling quality at the source.
Concluding there has not been an effect/change when there has.
Through producer/consumer negotiation.

24. When yields decrease - what are the two effects on contribution?
p-bar - the long-run percent defective.
Fewer good units to sell - increased variable cost/unit.
Variable.
=sqrt((p*(1-p)/n)

25. For what is a p-chart used?
A random variable that summarizes the information from the sample(s).
To monitor a process when measurement by attribute is used.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Linearity - normality - homoscedasticity - independence.

26. In the Service Quality Gap Model - what is Gap 1?
Central Limit Theorem
Taguchi
Brand image.
The gap between what management thinks customers want and what customers really want.

27. TWO-DIMENTIONAL SCATTER PLOT
Technical quality is the "what" of the service; functional quality is the "how."
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Scrap - rework - retest - downtime - yield losses - disposition costs.
Initiated before or at design concept finalization

28. What does SIPOC stand for?
Producer risk.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Supplier - input - process - output - customer.
Because the mean and standard deviation are independent of each other.

29. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Fitness for use.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

30. What is Type 1 Error?
Lower control limit.
The gap between what management thinks customers want and the process specifications.
Inventory = throughput x flow time.
Concluding there has been an effect/change when there has not.

31. What is the Deming Prize?
Walter A. Shewhart
A brainstorming tool that shows the connections between ideas.
The Japanese national quality award.
Someone who is consistently against virtually everything.

32. What is the role of a green belt?
To be a member of a Six Sigma project team.
5%
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Stratify a particular defect type according to logical criteria

33. What is the difference between Lean and Six Sigma?
The gap between what management thinks customers want and the process specifications.
Can't tell without a Range chart.
No -- if it is not the same - it can only be worse!
Lean is waste reduction - Six Sigma is variation reduction.

34. Who is a process owner?
5%
Prevention and appraisal costs are balanced against internal and external failure.
The manager in charge of a process being improved in a Six Sigma project.
An assertion or conjecture concerning one or more populations

35. What is a Pareto chart?
The US national quality award.
A descending order-sorted bar chart with a cumulative percentage line.
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
100%

36. Complete this quality phrase: 'Fix the process - not the _____.'
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The target number of standard deviations from the mean for specifications.
A random variable that summarizes the information from the sample(s).
Blame.

37. The Test Statistic (TS)
A random variable that summarizes the information from the sample(s).
No -- if it is not the same - it can only be worse!
A brainstorming tool that shows the connections between ideas.
The manager in charge of a process being improved in a Six Sigma project.

38. Your production process meets customer specifications. Is your process in control?
Not necessarily.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
To mentor/coach (and sometimes train) black belts.
Blame.

39. Test for constant variance
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.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Critical to quality.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

40. 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.
QFD
68%
Mistake-proofing.

41. In a regression - what does the coefficient of the intercept tell you
A tool that shows performance along key dimensions all at once.
Lower control limit.
What the value of the dependent variable is when the independent variable is zero.
Stratify a particular defect type according to logical criteria

42. Define durability.
Mean time to replacement.
Concluding there has been an effect/change when there has not.
Fractional factorial designs (orthogonal arrays)
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

43. One factor at a time (OFAT)
The manager in charge of a process being improved in a Six Sigma project.
Observed variation in response is caused by the input
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:
Central Limit Theorem

44. Definition of Interaction
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Causes that lead to a particular effect.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

45. What is Kaizen?
Critical to quality.
Variable.
A tool that shows the physical flows through a space.
Rapid improvement process.

46. Disadvantages of DOE

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47. In the Service Quality Gap Model - what is Gap 3?
The gap between specifications and how service is performed.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Critical to quality.
10 for Hazardous without warning 1 for none

48. What do you do when a process is out of control?
Through producer/consumer negotiation.
Is the consequence of the failure.
Outside.
Look for the assignable cause of non-random variation.

49. Risk Priority Number RPN
Brand image.
Rapid improvement process.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Taguchi

50. Effect ranking (Severity of the Defect)
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Technical quality is the "what" of the service; functional quality is the "how."
The ability of a process to consistently meet customer specifications.
10 for Hazardous without warning 1 for none