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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. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Outside.
The secondary characteristics of a product; "bells and whistles."
The gap between specifications and how service is performed.
Initiated before or at design concept finalization

2. Daniel Test
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:
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
X-bar-bar
False - because each machine will have different natural tolerances.

3. Disadvantages of DOE

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4. In a regression - what does the p value of F tell you?
10 for Hazardous without warning 1 for none
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).
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
Failure Modes and Effects Analysis

5. The Test Statistic (TS)
The secondary characteristics of a product; "bells and whistles."
Sort - Set in Order - Shine - Standardize - Sustain
A random variable that summarizes the information from the sample(s).
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

6. In Juran's Cost of Quality model - which categories of costs balance which other categories?
To obtain a certain desirable outcome from the process
No -- if it is not the same - it can only be worse!
=sqrt((p*(1-p)/n)
Prevention and appraisal costs are balanced against internal and external failure.

7. Which type of SPC measurement is more precise - variable or attribute?
Mean time to failure.
Variable.
It's good -- but it's still out of control!
Concluding there has not been an effect/change when there has.

8. What type of risk is associated with Type II Error?
Consumer risk.
p-bar - the long-run percent defective.
Outside.
The ability of a process to consistently meet customer specifications.

9. Uses of regression - Control
Sort - Set in Order - Shine - Standardize - Sustain
To obtain a certain desirable outcome from the process
Producer risk.
The primary operating characteristics of a product.

10. What is the Baldrige Award?
The US national quality award.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Mistake-proofing.
Concluding there has not been an effect/change when there has.

11. Define conformance quality.
What the value of the dependent variable is when the independent variable is zero.
The degree to which a product meets pre-established standards.
The gap between what management thinks customers want and the process specifications.
An assertion or conjecture concerning one or more populations

12. What are the Five Dimensions of Service Quality?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
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 gap between what management thinks customers want and the process specifications.
Blame.

13. Risk Priority Number RPN
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Brand image.
Causes that lead to a particular effect.
5%

14. Detection Criteria Ranking
10 if Almost impossible to detect
Lean is waste reduction - Six Sigma is variation reduction.
50%
Is the consequence of the failure.

15. With Six Sigma capability - how many defects per million opportunities would you see?
Producer risk.
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
To mentor/coach (and sometimes train) black belts.
3.4 (assuming 1.5 sigma shift in the mean)

16. Define durability.
Mean time to replacement.
Before production starts
=sqrt((p*(1-p)/n)
p-bar - the long-run percent defective.

17. Definition of Interaction
p-bar - the long-run percent defective.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Prevention - appraisal - internal failure - external failure.
Linearity - normality - homoscedasticity - independence.

18. Defect location check sheets
Actual drawings - layouts - maps - etc which show where a defect occurs
What the value of the dependent variable is when the independent variable is zero.
A tool that shows the physical flows through a space.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

19. Regression
Attribute
Concluding there has not been an effect/change when there has.
Represents the behavior of a process
An assertion or conjecture concerning one or more populations

20. Complete this quality phrase: 'Fix the process - not the _____.'
To obtain a certain desirable outcome from the process
Method developed by Ishikawa to graphically display the causes of any given problem
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Blame.

21. What is a dashboard?
A tool that shows performance along key dimensions all at once.
Prevention and appraisal costs are balanced against internal and external failure.
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.

22. What is written on the "spines" of a fishbone diagram?
Kaoru Ishikawa.
Deming.
Causes that lead to a particular effect.
Pleasing to the senses.

23. One factor at a time (OFAT)
To monitor a process when measurement by variables is used.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Hold all input variables constant except one. Observe the response as you vary the single input.
To monitor a process when measurement by attribute is used.

24. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Attribute
Can't tell without a Range chart.
Through producer/consumer negotiation.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

25. What is the formula for the standard deviation of a proportion?
= yij - y(bar)i --> value minus sum of that treatment (of row)
No -- only if the process is also capable.
The gap between specifications and how service is performed.
=sqrt((p*(1-p)/n)

26. What are the four regression assumptions?
Defects Per Million Opportunities
The number of standard deviations some value is from the mean.
Hold all input variables constant except one. Observe the response as you vary the single input.
Linearity - normality - homoscedasticity - independence.

27. 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.
Can't tell without a Range chart.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
It looks to minimize the probability of a failure - or to minimize its effects

28. Which quality guru developed the concept of loss to society?
0.9^3 or 72.9%
Observed variation in response is caused by the input
Taguchi
If the Response vs. Levels graph if the response lines are not parallel (crossing)

29. List Garvin's eight dimensions of product quality.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The ability of a process to consistently meet customer specifications.
=sqrt(Σ(x-x-bar)^2)/(n-1))

30. Does it ever make sense to accept a job when a process is incapable?
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 interaction is defined as a dependence relationship between the response and the levels of two or more variables
Can't tell without a Range chart.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

31. Define perceived quality (Garvin's framework).
Mistake-proofing.
Brand image.
Fishbone - cause-and-effect diagram.
The cycle time required to meet demand.

32. What is DPMO?
Defects Per Million Opportunities
Method developed by Ishikawa to graphically display the causes of any given problem
50%
Is the consequence of the failure.

33. What is a Gantt chart?
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
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.
Shows the temporal flow of activities in a project network.

34. What percentage of a normal distribution lies above the mean?
50%
The House of Quality.
Defects Per Million Opportunities
10 if Almost impossible to detect

35. What are the 5 Ss?
A descending order-sorted bar chart with a cumulative percentage line.
Mean time to replacement.
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
Sort - Set in Order - Shine - Standardize - Sustain

36. What does the abbreviation LCL stand for?
Lower control limit.
Hold all input variables constant except one. Observe the response as you vary the single input.
Central Limit Theorem
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

37. In a regression - what does R-square tell you?
The ability of a process to consistently meet customer specifications.
The ratio of outputs to inputs; 1-scrap.
Rapid improvement process.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

38. Define yield.
Producer risk.
Deming.
The Japanese national quality award.
The ratio of outputs to inputs; 1-scrap.

39. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Workers - machines - materials.
95%

40. What are the four categories of costs in Juran's framework?
Concluding there has been an effect/change when there has not.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Prevention - appraisal - internal failure - external failure.
Initiated before or at design concept finalization

41. What is process capability?
The ability of a process to consistently meet customer specifications.
Initiated before or at design concept finalization
68%
Scrap - rework - retest - downtime - yield losses - disposition costs.

42. DOE
Controlling quality at the source.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Lean (or JIT).
A tool that shows where there is waste in a process.

43. Your production process meets customer specifications. Is your process in control?
Not necessarily.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Define - measure - analyze - improve - control.
The gap between what is promised and what is delivered.

44. Define features.
To monitor a process when measurement by variables is used.
Fractional factorial designs (orthogonal arrays)
The secondary characteristics of a product; "bells and whistles."
A diagram that shows the relationships between activities in a project network.

45. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
95%
Attribute
10 for Hazardous without warning 1 for none
Before production starts

46. Presence of interaction effect
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
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)
Mean time to failure.

47. List two components of internal failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
The primary operating characteristics of a product.
Brand image.

48. What is a Gage R&R?
95%
Causes that lead to a particular effect.
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).
Not necessarily.

49. In the Service Quality Gap Model - what is Gap 1?
Large enough to find two of the attribute - on average.
50%
The gap between what customers expect and the service they receive.
The gap between what management thinks customers want and what customers really want.

50. Creating a Run Chart
Attribute
What the value of the dependent variable is when the independent variable is zero.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
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