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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. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
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
Conformance to specifications.
68%
Defects Per Million Opportunities

2. What quality tool formally incorporates the voice of the customer?
Represents the behavior of a process
10 for Hazardous without warning 1 for none
QFD
Conformance to specifications.

3. What is Type 1 Error?
Concluding there has been an effect/change when there has not.
Conformance to specifications.
Shifts - Trends - Repeating patterns - Correlation with known events
Failure Modes and Effects Analysis

4. Stratified defect check sheets
Before production starts
=sqrt((p*(1-p)/n)
Stratify a particular defect type according to logical criteria
Assigns scores to weighted criteria for each project under consideration.

5. DFMEA
Initiated before or at design concept finalization
Lower control limit.
Lower skill requirements - faster - less chance for error.
Technical quality is the "what" of the service; functional quality is the "how."

6. What is a CAVE man?
Sort - Set in Order - Shine - Standardize - Sustain
= yij - y(bar)i --> value minus sum of that treatment (of row)
Someone who is consistently against virtually everything.
Blame.

7. For what is an x-bar chart used?
To monitor a process when measurement by variables is used.
It's good -- but it's still out of control!
Workers - machines - materials.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

8. 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.
Scrap - rework - retest - downtime - yield losses - disposition costs.
To monitor a process when measurement by variables is used.
Prevention - appraisal - internal failure - external failure.

9. When is Cpk used?
Is the way in which the failure is manifested.
Technical quality is the "what" of the service; functional quality is the "how."
Mean time to replacement.
To do a capability study for a non-centered process.

10. What is poka yoke?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Lower control limit.
Consumer risk.
Mistake-proofing.

11. If you have calculated a Cpk - should you also calculate a Cp?
The ability of a process to consistently meet customer specifications.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
68%

12. Defect check sheets
The House of Quality.
Different types of defects are listed (used for Pareto chart)
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Represents the behavior of a process

13. What is a histogram?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
To be a member of a Six Sigma project team.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Controlling quality at the source.

14. The Test Statistic (TS)
Shifts - Trends - Repeating patterns - Correlation with known events
Workers - machines - materials.
The ability of a process to consistently meet customer specifications.
A random variable that summarizes the information from the sample(s).

15. What does a project prioritization matrix do?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
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 brainstorming tool that shows the connections between ideas.
Assigns scores to weighted criteria for each project under consideration.

16. What is the Deming Prize?
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
Deming.
The Japanese national quality award.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

17. How are LQL and AQL determined in an acceptance sampling plan?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Through producer/consumer negotiation.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Sampling for SPC is done real time.

18. Process occurance ranking
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The gap between specifications and how service is performed.
No -- the variation also has to be random and "expected."
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

19. In a regression - what does the coefficient of the intercept tell you
What the value of the dependent variable is when the independent variable is zero.
= 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
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
The secondary characteristics of a product; "bells and whistles."

20. You have been plotting sample means on an x-bar chart and all points indicate normal - expected variation. Is the process in control?

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21. Failure cause
Walter A. Shewhart
Can't tell without a Range chart.
Is the way in which the failure is manifested.
Is what induces the failure

22. What are the Five Dimensions of Service Quality?
Speed - courtesy - competence - and ease of repair.
Define - measure - analyze - improve - control.
Variable.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

23. What is an affinity diagram?
What the value of the dependent variable is when the independent variable is zero.
Blame.
A brainstorming tool that shows the connections between ideas.
To be a member of a Six Sigma project team.

24. With Six Sigma capability - how many defects per million opportunities would you see?
They move closer to the center line.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
3.4 (assuming 1.5 sigma shift in the mean)
No -- if it is not the same - it can only be worse!

25. A process is operating "in control." Does this mean the customer's requirements are met?
100%
No -- only if the process is also capable.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

26. List two components of external failure.
The ability of a process to consistently meet customer specifications.
X-bar-bar
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
10 for Hazardous without warning 1 for none

27. What is DMADV?
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
Mean time to replacement.
Define - measure - analyze - design - verify.
Shifts - Trends - Repeating patterns - Correlation with known events

28. What does the abbreviation UCL stand for?
Upper control limit.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
68%
Speed - courtesy - competence - and ease of repair.

29. In the Service Quality Gap Model - what is Gap 4?
Waste.
The gap between what is promised and what is delivered.
To manage the Six Sigma project.
Someone who is consistently against virtually everything.

30. What is Kaizen?
No -- only if the process is also capable.
Assigns scores to weighted criteria for each project under consideration.
Rapid improvement process.
A tool that shows performance along key dimensions all at once.

31. Statistical Hypothesis
A tool that shows where there is waste in a process.
To manage the Six Sigma project.
An assertion or conjecture concerning one or more populations
= yij - y(bar)i --> value minus sum of that treatment (of row)

32. TWO-DIMENTIONAL SCATTER PLOT
They move closer to the center line.
To manage the Six Sigma project.
Lower skill requirements - faster - less chance for error.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

33. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Failure Modes and Effects Analysis
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
95%
Reliability - Assurance - Responsiveness - Tangibles - Empathy

34. To what does the Six in Six Sigma relate?
Through producer/consumer negotiation.
The target number of standard deviations from the mean for specifications.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

35. 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?
Technical quality is the "what" of the service; functional quality is the "how."
The gap between what customers expect and the service they receive.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
False - because each machine will have different natural tolerances.

36. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
The gap between specifications and how service is performed.
To manage the Six Sigma project.
100%

37. Simple Regression Analysis (one factor regression model)
Different types of defects are listed (used for Pareto chart)
Upper control limit.
The secondary characteristics of a product; "bells and whistles."
= 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

38. What is the role of a master black belt?
To monitor a process when measurement by variables is used.
Causes that lead to a particular effect.
3.4 (assuming 1.5 sigma shift in the mean)
To mentor/coach (and sometimes train) black belts.

39. What is written on the "spines" of a fishbone diagram?
To manage the Six Sigma project.
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).
Sort - Set in Order - Shine - Standardize - Sustain
Causes that lead to a particular effect.

40. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Conformance to specifications.
Outside.
Mean time to failure.
=sqrt(Σ(x-x-bar)^2)/(n-1))

41. Define conformance quality.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The degree to which a product meets pre-established standards.
Define - measure - analyze - design - verify.

42. If you can only collect categorical data - what type of SPC charting can you do?
Attribute.
=sqrt((p*(1-p)/n)
Blame.
Sampling for SPC is done real time.

43. Define performance quality.
Is what induces the failure
If the Response vs. Levels graph if the response lines are not parallel (crossing)
The primary operating characteristics of a product.
Can't tell without a Range chart.

44. What is the formula for the standard deviation of a proportion?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
=sqrt((p*(1-p)/n)
A time series plot.
The US national quality award.

45. Explain the difference between technical and functional service quality.
Technical quality is the "what" of the service; functional quality is the "how."
The Japanese national quality award.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

46. Creating a Run Chart
Taguchi
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
It looks to minimize the probability of a failure - or to minimize its effects
Stratify a particular defect type according to logical criteria

47. Define features.
Attribute
The secondary characteristics of a product; "bells and whistles."
Conformance to specifications.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

48. What is the role of a black belt?
Is the way in which the failure is manifested.
To manage the Six Sigma project.
No -- if it is not the same - it can only be worse!
10 for Hazardous without warning 1 for none

49. Define takt time.
Someone who is consistently against virtually everything.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
95%
The cycle time required to meet demand.

50. For what is a p-chart used?
To monitor a process when measurement by attribute is used.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Speed - courtesy - competence - and ease of repair.
10 for Hazardous without warning 1 for none