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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. List two components of internal failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
A brainstorming tool that shows the connections between ideas.
p-bar - the long-run percent defective.
Failure Modes and Effects Analysis

2. Why do you need two control charts for variables SPC?
Mean time to failure.
Because the mean and standard deviation are independent of each other.
Deming.
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

3. Complete this quality phrase: 'Fix the process - not the _____.'
No -- the variation also has to be random and "expected."
To monitor a process when measurement by variables is used.
Blame.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

4. Define yield.
Lean is waste reduction - Six Sigma is variation reduction.
Actual drawings - layouts - maps - etc which show where a defect occurs
A diagram that shows the relationships between activities in a project network.
The ratio of outputs to inputs; 1-scrap.

5. Who developed the fishbone diagram?
Kaoru Ishikawa.
Fractional factorial designs (orthogonal arrays)
Look for the assignable cause of non-random variation.
A diagram that shows the relationships between activities in a project network.

6. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Supplier - input - process - output - customer.
68%
Central Limit Theorem
50%

7. One factor at a time (OFAT)
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:
Pleasing to the senses.
100%
Hold all input variables constant except one. Observe the response as you vary the single input.

8. What is the formula for standard deviation?
To mentor/coach (and sometimes train) black belts.
Supplier - input - process - output - customer.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Assigns scores to weighted criteria for each project under consideration.

9. Regression
Represents the behavior of a process
X-bar-bar
The degree to which a product meets pre-established standards.
Variable.

10. In the Service Quality Gap Model - what is Gap 1?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
If the Response vs. Levels graph if the response lines are not parallel (crossing)
The gap between what management thinks customers want and what customers really want.
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).

11. Pareto Analysis
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Mean time to replacement.
Prevention and appraisal costs are balanced against internal and external failure.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

12. What are the 5 Ss?
Consumer risk.
Sort - Set in Order - Shine - Standardize - Sustain
Attribute.
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:

13. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
An assertion or conjecture concerning one or more populations
Variable.
The cycle time required to meet demand.

14. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Workers - machines - materials.
Waste.
The gap between what management thinks customers want and the process specifications.
Conformance to specifications.

15. What are two other names for an Ishikawa diagram?
The gap between specifications and how service is performed.
A scatterplot.
Fishbone - cause-and-effect diagram.
Large enough to find two of the attribute - on average.

16. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
10 for Hazardous without warning 1 for none
Walter A. Shewhart
Upper control limit.
Lean (or JIT).

17. What is a dashboard?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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 tool that shows performance along key dimensions all at once.
The manager in charge of a process being improved in a Six Sigma project.

18. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Producer risk.
Lower skill requirements - faster - less chance for error.
Pleasing to the senses.

19. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
Lean (or JIT).
The secondary characteristics of a product; "bells and whistles."
Large enough to find two of the attribute - on average.

20. What is Type 1 Error?
Prevention - appraisal - internal failure - external failure.
p-bar - the long-run percent defective.
Concluding there has been an effect/change when there has not.
Central Limit Theorem

21. In the Service Quality Gap Model - what is Gap 3?
X-bar-bar
=sqrt((p*(1-p)/n)
The gap between specifications and how service is performed.
Used to create frequency distribution tally sheets

22. What is the Baldrige Award?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
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 US national quality award.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

23. Test for Independence
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
The secondary characteristics of a product; "bells and whistles."
Prevention and appraisal costs are balanced against internal and external failure.
No -- the variation also has to be random and "expected."

24. Define features.
Deming.
Upper control limit.
The secondary characteristics of a product; "bells and whistles."
Fitness for use.

25. Uses of regression - Control
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Mean time to failure.
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:
To obtain a certain desirable outcome from the process

26. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Observed variation in response is caused by the input
No -- the variation also has to be random and "expected."
The secondary characteristics of a product; "bells and whistles."
Pleasing to the senses.

27. List two appraisal costs.
= 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
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
To mentor/coach (and sometimes train) black belts.
Concluding there has not been an effect/change when there has.

28. Non-random patterns (Run Charts)
Shifts - Trends - Repeating patterns - Correlation with known events
To mentor/coach (and sometimes train) black belts.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Prevention and appraisal costs are balanced against internal and external failure.

29. Simple Regression Analysis (one factor regression model)
Mean time to failure.
= 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
To monitor a process when measurement by attribute is used.
Lower control limit.

30. In the Service Quality Gap Model - what is Gap 4?
Fitness for use.
The gap between what is promised and what is delivered.
No -- if it is not the same - it can only be worse!
3.4 (assuming 1.5 sigma shift in the mean)

31. What does SIPOC stand for?
Supplier - input - process - output - customer.
False - because each machine will have different natural tolerances.
Conformance to specifications.
Stratify a particular defect type according to logical criteria

32. Your production process meets customer specifications. Is your process in control?
Because the mean and standard deviation are independent of each other.
Not necessarily.
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.
Critical to quality.

33. What is a CAVE man?
The ability of a process to consistently meet customer specifications.
Waste.
Someone who is consistently against virtually everything.
The House of Quality.

34. What is CTQ?
The manager in charge of a process being improved in a Six Sigma project.
It's good -- but it's still out of control!
Critical to quality.
The House of Quality.

35. What is a Gage R&R?
Used to create frequency distribution tally sheets
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).
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Concluding there has not been an effect/change when there has.

36. Manual Test for Nomality
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Fishbone - cause-and-effect diagram.
Supplier - input - process - output - customer.
Is what induces the failure

37. Define durability.
A brainstorming tool that shows the connections between ideas.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Mean time to replacement.
No -- if it is not the same - it can only be worse!

38. What are the four perspectives of the Balanced Scorecard?
= yij - y(bar)i --> value minus sum of that treatment (of row)
Define - measure - analyze - improve - control.
Financial - customer - internal process - innovation and learning.
A tool that shows where there is waste in a process.

39. Define performance quality.
No -- only if the process is also capable.
p-bar - the long-run percent defective.
Kaoru Ishikawa.
The primary operating characteristics of a product.

40. Explain the difference between technical and functional service quality.
Variable.
The Japanese national quality award.
Technical quality is the "what" of the service; functional quality is the "how."
Assigns scores to weighted criteria for each project under consideration.

41. What is the role of a master black belt?
To mentor/coach (and sometimes train) black belts.
To monitor a process when measurement by variables is used.
No -- only if the process is also capable.
Variable.

42. PFMEA
Define - measure - analyze - improve - control.
Before production starts
Fractional factorial designs (orthogonal arrays)
Fewer good units to sell - increased variable cost/unit.

43. Process check sheets
Used to create frequency distribution tally sheets
Walter A. Shewhart
Defects Per Million Opportunities
Is the way in which the failure is manifested.

44. What does Crosby say about benchmarking?
Attribute
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Actual drawings - layouts - maps - etc which show where a defect occurs
The gap between specifications and how service is performed.

45. What is the Deming Prize?
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
Concluding there has been an effect/change when there has not.
Is the way in which the failure is manifested.
The Japanese national quality award.

46. One factor at a time (OFAT)
Observed variation in response is caused by the input
Initiated before or at design concept finalization
Concluding there has not been an effect/change when there has.
The Japanese national quality award.

47. For what is a p-chart used?
Lower control limit.
Conformance to specifications.
Look for the assignable cause of non-random variation.
To monitor a process when measurement by attribute is used.

48. Presence of interaction effect
A random variable that summarizes the information from the sample(s).
It's good -- but it's still out of control!
Fitness for use.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

49. Design of Experiments (DOE) approach
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
To be a member of a Six Sigma project team.
Is the way in which the failure is manifested.
Outside.

50. What is the role of a black belt?
The ratio of outputs to inputs; 1-scrap.
Prevention - appraisal - internal failure - external failure.
To manage the Six Sigma project.
5%