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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. When is Cpk used?
To do a capability study for a non-centered process.
Sampling for SPC is done real time.
Actual drawings - layouts - maps - etc which show where a defect occurs
A tool that shows performance along key dimensions all at once.

2. Define benchmarking.
Speed - courtesy - competence - and ease of repair.
Rapid improvement process.
Studying firms with the best performance in a particular area.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

3. What is Value Stream Mapping?
A tool that shows performance along key dimensions all at once.
A tool that shows where there is waste in a process.
Sampling for SPC is done real time.
Causes that lead to a particular effect.

4. Definition of Interaction
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
To do a capability study for a non-centered process.
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
X-bar-bar

5. What is the role of a black belt?
Mistake-proofing.
To manage the Six Sigma project.
The cycle time required to meet demand.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

6. What is a Gantt chart?
Shows the temporal flow of activities in a project network.
Fitness for use.
Variable.
The gap between what management thinks customers want and what customers really want.

7. Non-random patterns (Run Charts)
Shifts - Trends - Repeating patterns - Correlation with known events
A tool that shows the physical flows through a space.
Failure Modes and Effects Analysis
Waste.

8. What is DMADV?
F_alpha - df(tr) - df (error)
Define - measure - analyze - design - verify.
The secondary characteristics of a product; "bells and whistles."
A tool that shows where there is waste in a process.

9. What is a spaghetti diagram?
The target number of standard deviations from the mean for specifications.
Outside.
Financial - customer - internal process - innovation and learning.
A tool that shows the physical flows through a space.

10. What are the four perspectives of the Balanced Scorecard?
Financial - customer - internal process - innovation and learning.
The gap between what customers expect and the service they receive.
Hold all input variables constant except one. Observe the response as you vary the single input.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

11. TWO-DIMENTIONAL SCATTER PLOT
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
Inventory = throughput x flow time.
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

12. Define durability.
A tool that shows the physical flows through a space.
Mean time to replacement.
The House of Quality.
No -- the variation also has to be random and "expected."

13. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Method developed by Ishikawa to graphically display the causes of any given problem
Supplier - input - process - output - customer.

14. What is the Baldrige Award?
100%
It's good -- but it's still out of control!
Lower control limit.
The US national quality award.

15. What is Type 1 Error?
Concluding there has been an effect/change when there has not.
Consumer risk.
Failure Modes and Effects Analysis
False - because each machine will have different natural tolerances.

16. What is the role of a master black belt?
The primary operating characteristics of a product.
Concluding there has been an effect/change when there has not.
To mentor/coach (and sometimes train) black belts.
Speed - courtesy - competence - and ease of repair.

17. What are the four categories of costs in Juran's framework?
Prevention - appraisal - internal failure - external failure.
Mistake-proofing.
No -- if it is not the same - it can only be worse!
Before production starts

18. Failure effect
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Is the consequence of the failure.
Lean is waste reduction - Six Sigma is variation reduction.
The Japanese national quality award.

19. What is a dashboard?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
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).
A tool that shows performance along key dimensions all at once.
A descending order-sorted bar chart with a cumulative percentage line.

20. In a regression - what does R-square tell you?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The cycle time required to meet demand.
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
It looks to minimize the probability of a failure - or to minimize its effects

21. What is written on the "spines" of a fishbone diagram?
To monitor a process when measurement by variables is used.
Causes that lead to a particular effect.
The ability of a process to consistently meet customer specifications.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

22. To what does the Six in Six Sigma relate?
Failure Modes and Effects Analysis
The target number of standard deviations from the mean for specifications.
10 for Hazardous without warning 1 for none
=sqrt(Σ(x-x-bar)^2)/(n-1))

23. What is DPMO?
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 assertion or conjecture concerning one or more populations
Actual drawings - layouts - maps - etc which show where a defect occurs
Defects Per Million Opportunities

24. What is the formula for standard deviation?
No -- if it is not the same - it can only be worse!
Defects Per Million Opportunities
Critical to quality.
=sqrt(Σ(x-x-bar)^2)/(n-1))

25. What type of risk is associated with Type 1 Error?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Different types of defects are listed (used for Pareto chart)
Producer risk.
Is the way in which the failure is manifested.

26. What is a Gage R&R?
Used to create frequency distribution tally sheets
Deming.
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).
Different types of defects are listed (used for Pareto chart)

27. In a regression - what does the standard error of the estimate tell you?
Attribute
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Lean (or JIT).
F_alpha - df(tr) - df (error)

28. Stratified defect check sheets
Stratify a particular defect type according to logical criteria
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Sampling for SPC is done real time.
Mean time to failure.

29. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
99.73%
Studying firms with the best performance in a particular area.
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
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

30. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Lean (or JIT).
Is the consequence of the failure.
False - because each machine will have different natural tolerances.

31. Failure Mode
Hold all input variables constant except one. Observe the response as you vary the single input.
An assertion or conjecture concerning one or more populations
Is the way in which the failure is manifested.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

32. ANOVA

33. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Represents the behavior of a process
The number of standard deviations some value is from the mean.
Taguchi
No -- the variation also has to be random and "expected."

34. Detection Criteria Ranking
68%
Concluding there has not been an effect/change when there has.
Lean (or JIT).
10 if Almost impossible to detect

35. What is a histogram?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
The ability of a process to consistently meet customer specifications.
Large enough to find two of the attribute - on average.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

36. Affinity Diagrams
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
A random variable that summarizes the information from the sample(s).
10 for Hazardous without warning 1 for none
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

37. For what is an x-bar chart used?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
To manage the Six Sigma project.
To monitor a process when measurement by variables is used.
Through producer/consumer negotiation.

38. Effect ranking (Severity of the Defect)
Look for the assignable cause of non-random variation.
Blame.
10 for Hazardous without warning 1 for none
Before production starts

39. One factor at a time (OFAT)
A scatterplot.
Observed variation in response is caused by the input
Financial - customer - internal process - innovation and learning.
Failure Modes and Effects Analysis

40. What is Little's Law?
Mistake-proofing.
A scatterplot.
Inventory = throughput x flow time.
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. Define aesthetic quality.
Different types of defects are listed (used for Pareto chart)
Sampling for SPC is done real time.
Observed variation in response is caused by the input
Pleasing to the senses.

42. Who is a process owner?
QFD
The manager in charge of a process being improved in a Six Sigma project.
It's good -- but it's still out of control!
Prevention - appraisal - internal failure - external failure.

43. What is the 5S model?
Attribute
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

44. A process is operating "in control." Does this mean the customer's requirements are met?
Attribute
Lower skill requirements - faster - less chance for error.
No -- only if the process is also capable.
Supplier - input - process - output - customer.

45. DOE
What the value of the dependent variable is when the independent variable is zero.
= yij - y(bar)i --> value minus sum of that treatment (of row)
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

46. Simple Regression Analysis (one factor regression model)
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
= 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
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
The manager in charge of a process being improved in a Six Sigma project.

47. 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?
Someone who is consistently against virtually everything.
False - because each machine will have different natural tolerances.
10 if Almost impossible to detect
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:

48. Presence of interaction effect
Stratify a particular defect type according to logical criteria
A tool that shows the physical flows through a space.
Initiated before or at design concept finalization
If the Response vs. Levels graph if the response lines are not parallel (crossing)

49. F value
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
F_alpha - df(tr) - df (error)
Fitness for use.

50. What type of risk is associated with Type II Error?
Is what induces the failure
Upper control limit.
Lean (or JIT).
Consumer risk.