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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. What does a project prioritization matrix do?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Before production starts
Used to create frequency distribution tally sheets
Assigns scores to weighted criteria for each project under consideration.

2. What is the role of a master black belt?
Can't tell without a Range chart.
Fitness for use.
To mentor/coach (and sometimes train) black belts.
Prevention - appraisal - internal failure - external failure.

3. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
=sqrt(Σ(x-x-bar)^2)/(n-1))
5%
Attribute.

4. Residual
Mean time to replacement.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Assigns scores to weighted criteria for each project under consideration.
A diagram that shows the relationships between activities in a project network.

5. Which quality guru developed the concept of loss to society?
10 for Hazardous without warning 1 for none
Taguchi
50%
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

6. Define serviceability.
Hold all input variables constant except one. Observe the response as you vary the single input.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Producer risk.
Speed - courtesy - competence - and ease of repair.

7. In a regression - what does the standard error of the estimate tell you?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The ability of a process to consistently meet customer specifications.
No -- only if the process is also capable.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

8. PFMEA
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Defects Per Million Opportunities
Before production starts
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

9. What are the four regression assumptions?
Before production starts
= yij - y(bar)i --> value minus sum of that treatment (of row)
Linearity - normality - homoscedasticity - independence.
Attribute.

10. What is the center line of a p-chart?
Sampling for SPC is done real time.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
p-bar - the long-run percent defective.
What the value of the dependent variable is when the independent variable is zero.

11. What are the Five Dimensions of Service Quality?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Variable.
Brand image.
Because the mean and standard deviation are independent of each other.

12. In the Service Quality Gap Model - what is Gap 3?
Sort - Set in Order - Shine - Standardize - Sustain
Taguchi
They move closer to the center line.
The gap between specifications and how service is performed.

13. Uses of regression - Control
= yij - y(bar)i --> value minus sum of that treatment (of row)
Attribute.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
To obtain a certain desirable outcome from the process

14. In the Service Quality Gap Model - what is Gap 4?
Pleasing to the senses.
The gap between what is promised and what is delivered.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
To obtain a certain desirable outcome from the process

15. Defect location check sheets
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
Central Limit Theorem
68%
Actual drawings - layouts - maps - etc which show where a defect occurs

16. What is DPMO?
A time series plot.
No -- only if the process is also capable.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Defects Per Million Opportunities

17. When yields decrease - what are the two effects on contribution?
A brainstorming tool that shows the connections between ideas.
Fewer good units to sell - increased variable cost/unit.
Speed - courtesy - competence - and ease of repair.
The number of standard deviations some value is from the mean.

18. What percentage of a normal distribution lies above the mean?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
50%
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Sampling for SPC is done real time.

19. Advantages of DOE
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
= 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
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
A diagram that shows the relationships between activities in a project network.

20. What size should samples be for attribute SPC?
Sampling for SPC is done real time.
A tool that shows where there is waste in a process.
Large enough to find two of the attribute - on average.
F_alpha - df(tr) - df (error)

21. What does the abbreviation UCL stand for?
Upper control limit.
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
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
The House of Quality.

22. List two components of external failure.
A scatterplot.
The degree to which a product meets pre-established standards.
Prevention and appraisal costs are balanced against internal and external failure.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

23. What is the role of a black belt?
Organize ideas into meaningful categories by recognizing their underlying similarity
A time series plot.
To manage the Six Sigma project.
The gap between what is promised and what is delivered.

24. F value
Deming.
QFD
Defects Per Million Opportunities
F_alpha - df(tr) - df (error)

25. In a regression - what does R-square tell you?
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).
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
To do a capability study for a non-centered process.
The gap between what management thinks customers want and what customers really want.

26. Risk Priority Number RPN
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
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
To monitor a process when measurement by variables is used.
Mean time to failure.

27. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Attribute
The secondary characteristics of a product; "bells and whistles."
A tool that shows the physical flows through a space.
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).

28. What is a CAVE man?
Shows the temporal flow of activities in a project network.
Someone who is consistently against virtually everything.
The US national quality award.
To monitor a process when measurement by variables is used.

29. Daniel Test
The cycle time required to meet demand.
Organize ideas into meaningful categories by recognizing their underlying similarity
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:
Lower control limit.

30. What is a Pareto chart?
A descending order-sorted bar chart with a cumulative percentage line.
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
Technical quality is the "what" of the service; functional quality is the "how."
0.9^3 or 72.9%

31. Define durability.
Mean time to replacement.
No -- the variation also has to be random and "expected."
Initiated before or at design concept finalization
Conformance to specifications.

32. FMEA
Is what induces the failure
Supplier - input - process - output - customer.
The target number of standard deviations from the mean for specifications.
It looks to minimize the probability of a failure - or to minimize its effects

33. Statistical Hypothesis
An assertion or conjecture concerning one or more populations
Waste.
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).
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

34. Taguchi's experimental designs are of this type.
Observed variation in response is caused by the input
Sort - Set in Order - Shine - Standardize - Sustain
Fractional factorial designs (orthogonal arrays)
Lean (or JIT).

35. In the Service Quality Gap Model - what is Gap 5?
p-bar - the long-run percent defective.
It's good -- but it's still out of control!
The gap between what customers expect and the service they receive.
Lean (or JIT).

36. Which type of SPC measurement is more precise - variable or attribute?
Variable.
Kaoru Ishikawa.
68%
Different types of defects are listed (used for Pareto chart)

37. What are the 5 Ss?
Upper control limit.
Sort - Set in Order - Shine - Standardize - Sustain
Causes that lead to a particular effect.
To obtain a certain desirable outcome from the process

38. Who first studied randomness in industrial processes
They move closer to the center line.
Walter A. Shewhart
3.4 (assuming 1.5 sigma shift in the mean)
The secondary characteristics of a product; "bells and whistles."

39. Effect ranking (Severity of the Defect)
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 cycle time required to meet demand.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
10 for Hazardous without warning 1 for none

40. What is the formula for the standard deviation of a proportion?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Kaoru Ishikawa.
=sqrt((p*(1-p)/n)
The gap between what management thinks customers want and what customers really want.

41. ANOVA

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42. What is Kaizen?
Is the way in which the failure is manifested.
Rapid improvement process.
The gap between what management thinks customers want and what customers really want.
Represents the behavior of a process

43. How are LQL and AQL determined in an acceptance sampling plan?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Through producer/consumer negotiation.
Pleasing to the senses.
To do a capability study for a non-centered process.

44. For what is an x-bar chart used?
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
To monitor a process when measurement by variables is used.
They move closer to the center line.
A scatterplot.

45. What is CTQ?
Assigns scores to weighted criteria for each project under consideration.
Critical to quality.
Mistake-proofing.
A descending order-sorted bar chart with a cumulative percentage line.

46. Process check sheets
Mistake-proofing.
0.9^3 or 72.9%
Used to create frequency distribution tally sheets
To obtain a certain desirable outcome from the process

47. To what does the Six in Six Sigma relate?
A random variable that summarizes the information from the sample(s).
p-bar - the long-run percent defective.
=sqrt((p*(1-p)/n)
The target number of standard deviations from the mean for specifications.

48. Your production process meets customer specifications. Is your process in control?
Taguchi
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
The ability of a process to consistently meet customer specifications.
Not necessarily.

49. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
68%
Financial - customer - internal process - innovation and learning.
No -- only if the process is also capable.
Brand image.

50. What is the Deming Prize?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Used to create frequency distribution tally sheets
The Japanese national quality award.
Linearity - normality - homoscedasticity - independence.