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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 are the four perspectives of the Balanced Scorecard?
No -- if it is not the same - it can only be worse!
95%
Financial - customer - internal process - innovation and learning.
= yij - y(bar)i --> value minus sum of that treatment (of row)

2. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Reliability - Assurance - Responsiveness - Tangibles - Empathy
It's good -- but it's still out of control!
Lean (or JIT).
Initiated before or at design concept finalization

3. Failure effect
10 if Almost impossible to detect
Is the consequence of the failure.
Is what induces the failure
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

4. What is Little's Law?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
The target number of standard deviations from the mean for specifications.
Define - measure - analyze - design - verify.
Inventory = throughput x flow time.

5. What is written on the "spines" of a fishbone diagram?
Someone who is consistently against virtually everything.
Causes that lead to a particular effect.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
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).

6. What quality guru emphasizes management as a system?
Deming.
Attribute.
Walter A. Shewhart
Taguchi

7. What is the Deming Prize?
Consumer risk.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
The Japanese national quality award.
To mentor/coach (and sometimes train) black belts.

8. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Pleasing to the senses.
The primary operating characteristics of a product.
The gap between what management thinks customers want and the process specifications.

9. What is a histogram?
Attribute.
Waste.
Walter A. Shewhart
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

10. Define product reliability.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Variable.
Rapid improvement process.
Mean time to failure.

11. In the Service Quality Gap Model - what is Gap 4?
Through producer/consumer negotiation.
Supplier - input - process - output - customer.
The gap between what is promised and what is delivered.
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:

12. Define performance quality.
A tool that shows where there is waste in a process.
To be a member of a Six Sigma project team.
It's good -- but it's still out of control!
The primary operating characteristics of a product.

13. What is the role of a green belt?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Mistake-proofing.
To be a member of a Six Sigma project team.
Outside.

14. What are the 5 Ss?
To manage the Six Sigma project.
Sort - Set in Order - Shine - Standardize - Sustain
The cycle time required to meet demand.
Controlling quality at the source.

15. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
Variable.
Fishbone - cause-and-effect diagram.
Financial - customer - internal process - innovation and learning.

16. What are the three main categories of assignable cause?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Lower skill requirements - faster - less chance for error.
Workers - machines - materials.
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).

17. DFMEA
Initiated before or at design concept finalization
The Japanese national quality award.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
The manager in charge of a process being improved in a Six Sigma project.

18. 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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19. What does a project prioritization matrix do?
The House of Quality.
Is the way in which the failure is manifested.
Assigns scores to weighted criteria for each project under consideration.
Failure Modes and Effects Analysis

20. Residual
Mean time to replacement.
The ratio of outputs to inputs; 1-scrap.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
= 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

21. What is the center line of an X-bar chart?
An assertion or conjecture concerning one or more populations
Pleasing to the senses.
Is the consequence of the failure.
X-bar-bar

22. Define durability.
Method developed by Ishikawa to graphically display the causes of any given problem
Producer risk.
Variable.
Mean time to replacement.

23. What is FMEA?
False - because each machine will have different natural tolerances.
Concluding there has not been an effect/change when there has.
Failure Modes and Effects Analysis
Attribute

24. Uses of regression - Control
100%
Financial - customer - internal process - innovation and learning.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
To obtain a certain desirable outcome from the process

25. When is Cpk used?
To do a capability study for a non-centered process.
Pleasing to the senses.
Defects Per Million Opportunities
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

26. Creating a Run Chart
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
The degree to which a product meets pre-established standards.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Walter A. Shewhart

27. In the Service Quality Gap Model - what is Gap 3?
=sqrt(Σ(x-x-bar)^2)/(n-1))
The US national quality award.
The gap between specifications and how service is performed.
100%

28. What do you do when a process is out of control?
Inventory = throughput x flow time.
The cycle time required to meet demand.
Before production starts
Look for the assignable cause of non-random variation.

29. Simple Regression Analysis (one factor regression model)
False - because each machine will have different natural tolerances.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Walter A. Shewhart
= 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

30. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Fewer good units to sell - increased variable cost/unit.
It looks to minimize the probability of a failure - or to minimize its effects
Attribute
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

31. What is DMADV?
The gap between what management thinks customers want and what customers really want.
Can't tell without a Range chart.
Define - measure - analyze - design - verify.
95%

32. Risk Priority Number RPN
Stratify a particular defect type according to logical criteria
The Japanese national quality award.
Assigns scores to weighted criteria for each project under consideration.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

33. Histogram by Hand
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Sort - Set in Order - Shine - Standardize - Sustain
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
Mistake-proofing.

34. Design of Experiments (DOE) approach
The secondary characteristics of a product; "bells and whistles."
Taguchi
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Supplier - input - process - output - customer.

35. If you can only collect categorical data - what type of SPC charting can you do?
The Japanese national quality award.
To manage the Six Sigma project.
The manager in charge of a process being improved in a Six Sigma project.
Attribute.

36. What is Type II Error?
Concluding there has not been an effect/change when there has.
The gap between what management thinks customers want and what customers really want.
Prevention - appraisal - internal failure - external failure.
Shifts - Trends - Repeating patterns - Correlation with known events

37. What is a network diagram?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Kaoru Ishikawa.
The number of standard deviations some value is from the mean.
A diagram that shows the relationships between activities in a project network.

38. TWO-DIMENTIONAL SCATTER PLOT
95%
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 target number of standard deviations from the mean for specifications.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

39. What is a Pareto chart?
No -- if it is not the same - it can only be worse!
A descending order-sorted bar chart with a cumulative percentage line.
To mentor/coach (and sometimes train) black belts.
Scrap - rework - retest - downtime - yield losses - disposition costs.

40. What quality tool formally incorporates the voice of the customer?
Method developed by Ishikawa to graphically display the causes of any given problem
A descending order-sorted bar chart with a cumulative percentage line.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
QFD

41. What is poka yoke?
Mistake-proofing.
No -- if it is not the same - it can only be worse!
Look for the assignable cause of non-random variation.
The degree to which a product meets pre-established standards.

42. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Consumer risk.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Attribute
Variable.

43. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Workers - machines - materials.
68%
Stratify a particular defect type according to logical criteria
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

44. Does it ever make sense to accept a job when a process is incapable?
Shifts - Trends - Repeating patterns - Correlation with known events
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Waste.
A diagram that shows the relationships between activities in a project network.

45. In a regression - what does the p value of F tell you?
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).
3.4 (assuming 1.5 sigma shift in the mean)
Because the mean and standard deviation are independent of each other.
50%

46. If a three-stage process has 90% yields at each stage - what is the overall yield?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Conformance to specifications.
Fewer good units to sell - increased variable cost/unit.
0.9^3 or 72.9%

47. Define takt time.
A time series plot.
Variable.
The cycle time required to meet demand.
Walter A. Shewhart

48. In the Service Quality Gap Model - what is Gap 1?
The gap between what management thinks customers want and what customers really want.
Used to create frequency distribution tally sheets
Consumer risk.
Attribute

49. The Test Statistic (TS)
95%
Outside.
A random variable that summarizes the information from the sample(s).
Critical to quality.

50. 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?
Attribute
Can't tell without a Range chart.
Failure Modes and Effects Analysis
False - because each machine will have different natural tolerances.