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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. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
X-bar-bar
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
No -- the variation also has to be random and "expected."
The number of standard deviations some value is from the mean.

2. Histogram by Hand
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Before production starts
No -- if it is not the same - it can only be worse!
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

3. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
To obtain a certain desirable outcome from the process
100%
Mistake-proofing.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

4. What is the role of a master black belt?
Lean is waste reduction - Six Sigma is variation reduction.
Can't tell without a Range chart.
To mentor/coach (and sometimes train) black belts.
Assigns scores to weighted criteria for each project under consideration.

5. Disadvantages of DOE

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6. In a regression - what does R-square tell you?
=sqrt(Σ(x-x-bar)^2)/(n-1))
50%
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Define - measure - analyze - improve - control.

7. What does a project prioritization matrix do?
Mean time to failure.
No -- only if the process is also capable.
Mean time to replacement.
Assigns scores to weighted criteria for each project under consideration.

8. F value
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Is the way in which the failure is manifested.
Supplier - input - process - output - customer.
F_alpha - df(tr) - df (error)

9. List Garvin's eight dimensions of product quality.
Inventory = throughput x flow time.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Assigns scores to weighted criteria for each project under consideration.
Brand image.

10. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
To do a capability study for a non-centered process.
Supplier - input - process - output - customer.
Causes that lead to a particular effect.
Lower skill requirements - faster - less chance for error.

11. For what is an x-bar chart used?
Sampling for SPC is done real time.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Assigns scores to weighted criteria for each project under consideration.
To monitor a process when measurement by variables is used.

12. FMEA
Inventory = throughput x flow time.
A descending order-sorted bar chart with a cumulative percentage line.
It looks to minimize the probability of a failure - or to minimize its effects
The ratio of outputs to inputs; 1-scrap.

13. How are LQL and AQL determined in an acceptance sampling plan?
Fitness for use.
Concluding there has not been an effect/change when there has.
No -- only if the process is also capable.
Through producer/consumer negotiation.

14. Uses of regression
Speed - courtesy - competence - and ease of repair.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
It looks to minimize the probability of a failure - or to minimize its effects
The gap between what is promised and what is delivered.

15. ANOVA

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16. Define durability.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Mean time to replacement.
Before production starts
Large enough to find two of the attribute - on average.

17. What is the center line of an X-bar chart?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Variable.
To monitor a process when measurement by variables is used.
X-bar-bar

18. What is DMADV?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Concluding there has been an effect/change when there has not.
Define - measure - analyze - design - verify.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

19. In a Z table - what is Z?
The number of standard deviations some value is from the mean.
A descending order-sorted bar chart with a cumulative percentage line.
Technical quality is the "what" of the service; functional quality is the "how."
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

20. Who developed the fishbone diagram?
Speed - courtesy - competence - and ease of repair.
Concluding there has been an effect/change when there has not.
The Japanese national quality award.
Kaoru Ishikawa.

21. Who first studied randomness in industrial processes
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Walter A. Shewhart
Shows the temporal flow of activities in a project network.
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).

22. Risk Priority Number RPN
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Variable.
A descending order-sorted bar chart with a cumulative percentage line.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

23. Regression Analysis
Prevention - appraisal - internal failure - external failure.
The ability of a process to consistently meet customer specifications.
Is what induces the failure
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

24. What type of risk is associated with Type II Error?
Kaoru Ishikawa.
The US national quality award.
The secondary characteristics of a product; "bells and whistles."
Consumer risk.

25. What happens to control limits on an SPC chart when sample size is increased?
Linearity - normality - homoscedasticity - independence.
QFD
50%
They move closer to the center line.

26. What percentage of a normal distribution lies above the mean?
Is the consequence of the failure.
Define - measure - analyze - improve - control.
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
50%

27. Process check sheets
An assertion or conjecture concerning one or more populations
Used to create frequency distribution tally sheets
A descending order-sorted bar chart with a cumulative percentage line.
Fitness for use.

28. What are the four regression assumptions?
No -- if it is not the same - it can only be worse!
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Fitness for use.
Linearity - normality - homoscedasticity - independence.

29. Defect check sheets
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Different types of defects are listed (used for Pareto chart)
F_alpha - df(tr) - df (error)
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

30. When yields decrease - what are the two effects on contribution?
Fewer good units to sell - increased variable cost/unit.
Hold all input variables constant except one. Observe the response as you vary the single input.
Used to create frequency distribution tally sheets
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

31. What is process capability?
Taguchi
Linearity - normality - homoscedasticity - independence.
Fishbone - cause-and-effect diagram.
The ability of a process to consistently meet customer specifications.

32. What is Kaizen?
Because the mean and standard deviation are independent of each other.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Rapid improvement process.
An assertion or conjecture concerning one or more populations

33. What is the role of a green belt?
To be a member of a Six Sigma project team.
Hold all input variables constant except one. Observe the response as you vary the single input.
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
It's good -- but it's still out of control!

34. The data points on an SPC p-chart of defective percent plot below the mean. Is this good or bad?

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35. Define benchmarking.
= yij - y(bar)i --> value minus sum of that treatment (of row)
The gap between what management thinks customers want and the process specifications.
Studying firms with the best performance in a particular area.
Fractional factorial designs (orthogonal arrays)

36. 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.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Fitness for use.
Sort - Set in Order - Shine - Standardize - Sustain

37. Defect location check sheets
Actual drawings - layouts - maps - etc which show where a defect occurs
The gap between specifications and how service is performed.
Concluding there has been an effect/change when there has not.
The US national quality award.

38. What is a Gantt chart?
To be a member of a Six Sigma project team.
Shows the temporal flow of activities in a project network.
A diagram that shows the relationships between activities in a project network.
To monitor a process when measurement by attribute is used.

39. What are the four perspectives of the Balanced Scorecard?
Kaoru Ishikawa.
Financial - customer - internal process - innovation and learning.
To be a member of a Six Sigma project team.
=sqrt((p*(1-p)/n)

40. Why do you need two control charts for variables SPC?
Large enough to find two of the attribute - on average.
Because the mean and standard deviation are independent of each other.
Define - measure - analyze - design - verify.
Attribute.

41. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Outside.
Taguchi
To obtain a certain desirable outcome from the process
Variable.

42. If a Cp shows that a process is not capable - should you calculate Cpk?
A tool that shows performance along key dimensions all at once.
No -- if it is not the same - it can only be worse!
Controlling quality at the source.
Is what induces the failure

43. What is a Gage R&R?
50%
Look for the assignable cause of non-random variation.
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).
To monitor a process when measurement by variables is used.

44. Daniel Test
Studying firms with the best performance in a particular area.
Blame.
=sqrt((p*(1-p)/n)
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:

45. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
Speed - courtesy - competence - and ease of repair.
Concluding there has been an effect/change when there has not.
It's good -- but it's still out of control!

46. One factor at a time (OFAT)
Causes that lead to a particular effect.
The Japanese national quality award.
False - because each machine will have different natural tolerances.
Observed variation in response is caused by the input

47. Advantages of DOE
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The US national quality award.
Initiated before or at design concept finalization
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

48. Affinity Diagrams
Represents the behavior of a process
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Observed variation in response is caused by the input
100%

49. In the Service Quality Gap Model - what is Gap 5?
Define - measure - analyze - improve - control.
The gap between what customers expect and the service they receive.
The secondary characteristics of a product; "bells and whistles."
Reliability - Assurance - Responsiveness - Tangibles - Empathy

50. Define yield.
Causes that lead to a particular effect.
The ratio of outputs to inputs; 1-scrap.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
To obtain a certain desirable outcome from the process