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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. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
The gap between what management thinks customers want and what customers really want.
Waste.
Prevention - appraisal - internal failure - external failure.

2. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Look for the assignable cause of non-random variation.
A diagram that shows the relationships between activities in a project network.
= yij - y(bar)i --> value minus sum of that treatment (of row)
99.73%

3. What are the four perspectives of the Balanced Scorecard?
To monitor a process when measurement by variables is used.
Supplier - input - process - output - customer.
Speed - courtesy - competence - and ease of repair.
Financial - customer - internal process - innovation and learning.

4. A process is operating "in control." Does this mean the customer's requirements are met?
Sampling for SPC is done real time.
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).
No -- only if the process is also capable.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

5. In the Service Quality Gap Model - what is Gap 5?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
The gap between what customers expect and the service they receive.
95%
Prevention and appraisal costs are balanced against internal and external failure.

6. What quality tool formally incorporates the voice of the customer?
QFD
To monitor a process when measurement by attribute is used.
Concluding there has been an effect/change when there has not.
95%

7. One factor at a time (OFAT)
=sqrt((p*(1-p)/n)
To mentor/coach (and sometimes train) black belts.
Hold all input variables constant except one. Observe the response as you vary the single input.
Producer risk.

8. Process check sheets
Used to create frequency distribution tally sheets
No -- if it is not the same - it can only be worse!
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
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

9. Does it ever make sense to accept a job when a process is incapable?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
3.4 (assuming 1.5 sigma shift in the mean)
To obtain a certain desirable outcome from the process

10. Which quality guru developed the concept of loss to society?
Taguchi
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
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.

11. Define product reliability.
Mean time to failure.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Lower control limit.
Organize ideas into meaningful categories by recognizing their underlying similarity

12. Define perceived quality (Garvin's framework).
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
Central Limit Theorem
Brand image.
The gap between what management thinks customers want and what customers really want.

13. Advantages of DOE
Can't tell without a Range 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
Initiated before or at design concept finalization
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

14. Which type of SPC measurement is more precise - variable or attribute?
Attribute
Initiated before or at design concept finalization
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).
Variable.

15. What does the abbreviation LCL stand for?
Is the consequence of the failure.
Variable.
Lower control limit.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

16. What is written on the "spines" of a fishbone diagram?
A scatterplot.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Causes that lead to a particular effect.
The gap between what management thinks customers want and what customers really want.

17. The data points on an SPC p-chart of defective percent plot below the mean. Is this good or bad?

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18. Failure Mode
Waste.
Is the way in which the failure is manifested.
The gap between what management thinks customers want and what customers really want.
What the value of the dependent variable is when the independent variable is zero.

19. Simple Regression Analysis (one factor regression model)
= 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
Walter A. Shewhart
Pleasing to the senses.
To manage the Six Sigma project.

20. What size should samples be for attribute SPC?
Is the consequence of the failure.
Before production starts
Controlling quality at the source.
Large enough to find two of the attribute - on average.

21. Process occurance ranking
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
False - because each machine will have different natural tolerances.
Fewer good units to sell - increased variable cost/unit.
Initiated before or at design concept finalization

22. 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
A time series plot.
The gap between specifications and how service is performed.
The gap between what management thinks customers want and what customers really want.

23. F value
F_alpha - df(tr) - df (error)
A tool that shows performance along key dimensions all at once.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

24. What does SIPOC stand for?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
No -- only if the process is also capable.
Linearity - normality - homoscedasticity - independence.
Supplier - input - process - output - customer.

25. What is a Gantt chart?
Lower skill requirements - faster - less chance for error.
The US national quality award.
Shows the temporal flow of activities in a project network.
Conformance to specifications.

26. Definition of Interaction
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Concluding there has not been an effect/change when there has.
Hold all input variables constant except one. Observe the response as you vary the single input.
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

27. What is process capability?
The ability of a process to consistently meet customer specifications.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Mistake-proofing.
A scatterplot.

28. How does Juran define quality?
Producer risk.
Organize ideas into meaningful categories by recognizing their underlying similarity
Fitness for use.
The ratio of outputs to inputs; 1-scrap.

29. Risk Priority Number RPN
The US national quality award.
Variable.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Consumer risk.

30. What is muda
= yij - y(bar)i --> value minus sum of that treatment (of row)
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Waste.

31. What are the three main categories of assignable cause?
Workers - machines - materials.
Waste.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Actual drawings - layouts - maps - etc which show where a defect occurs

32. What is Kaizen?
Deming.
Rapid improvement process.
An assertion or conjecture concerning one or more populations
QFD

33. Test for Independence
The ability of a process to consistently meet customer specifications.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
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
They move closer to the center line.

34. List two components of internal failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Actual drawings - layouts - maps - etc which show where a defect occurs
Technical quality is the "what" of the service; functional quality is the "how."
=sqrt((p*(1-p)/n)

35. What is a CAVE man?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Large enough to find two of the attribute - on average.
The target number of standard deviations from the mean for specifications.
Someone who is consistently against virtually everything.

36. List two appraisal costs.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Shifts - Trends - Repeating patterns - Correlation with known events
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
To monitor a process when measurement by variables is used.

37. Your production process meets customer specifications. Is your process in control?
To do a capability study for a non-centered process.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Not necessarily.
Actual drawings - layouts - maps - etc which show where a defect occurs

38. Residual
To monitor a process when measurement by attribute is used.
The ability of a process to consistently meet customer specifications.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Lean (or JIT).

39. What is the 5S model?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
To monitor a process when measurement by variables is used.
No -- only if the process is also capable.

40. What is the role of a master black belt?
Sampling for SPC is done real time.
Actual drawings - layouts - maps - etc which show where a defect occurs
To mentor/coach (and sometimes train) black belts.
It's good -- but it's still out of control!

41. In the Service Quality Gap Model - what is Gap 3?
The gap between specifications and how service is performed.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
The secondary characteristics of a product; "bells and whistles."
A time series plot.

42. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Deming.
Controlling quality at the source.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Lower skill requirements - faster - less chance for error.

43. Define serviceability.
Speed - courtesy - competence - and ease of repair.
An assertion or conjecture concerning one or more populations
The secondary characteristics of a product; "bells and whistles."
Because the mean and standard deviation are independent of each other.

44. If you can only collect categorical data - what type of SPC charting can you do?
Attribute.
Sampling for SPC is done real time.
10 if Almost impossible to detect
To do a capability study for a non-centered process.

45. What is CTQ?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Variable.
Critical to quality.
Linearity - normality - homoscedasticity - independence.

46. Effect ranking (Severity of the Defect)
Central Limit Theorem
10 for Hazardous without warning 1 for none
Fractional factorial designs (orthogonal arrays)
Studying firms with the best performance in a particular area.

47. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
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.
Conformance to specifications.
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. If a three-stage process has 90% yields at each stage - what is the overall yield?
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
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).
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
0.9^3 or 72.9%

49. What is the Deming Prize?
The Japanese national quality award.
Speed - courtesy - competence - and ease of repair.
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
Walter A. Shewhart

50. Define aesthetic quality.
Pleasing to the senses.
68%
Speed - courtesy - competence - and ease of repair.
A time series plot.