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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. ANOVA

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2. Who developed the fishbone diagram?
Kaoru Ishikawa.
It looks to minimize the probability of a failure - or to minimize its effects
Variable.
Concluding there has not been an effect/change when there has.

3. What is the difference between Lean and Six Sigma?
Controlling quality at the source.
Lean is waste reduction - Six Sigma is variation reduction.
Mistake-proofing.
The gap between specifications and how service is performed.

4. What is a CAVE man?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Someone who is consistently against virtually everything.
The ability of a process to consistently meet customer specifications.
Supplier - input - process - output - customer.

5. What is the 5S model?
The Japanese 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.
Blame.
A descending order-sorted bar chart with a cumulative percentage line.

6. What is a histogram?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Defects Per Million Opportunities
What the value of the dependent variable is when the independent variable is zero.
Lean is waste reduction - Six Sigma is variation reduction.

7. Your production process meets customer specifications. Is your process in control?
Failure Modes and Effects Analysis
To obtain a certain desirable outcome from the process
Attribute
Not necessarily.

8. What is a Gantt chart?
Failure Modes and Effects Analysis
Fewer good units to sell - increased variable cost/unit.
Shows the temporal flow of activities in a project network.
Is what induces the failure

9. In the Service Quality Gap Model - what is Gap 3?
Financial - customer - internal process - innovation and learning.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The gap between specifications and how service is performed.
50%

10. TWO-DIMENTIONAL SCATTER PLOT
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
The degree to which a product meets pre-established standards.
Brand image.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

11. Detection Criteria Ranking
Brand image.
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 gap between specifications and how service is performed.
10 if Almost impossible to detect

12. Creating a Run Chart
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
If the Response vs. Levels graph if the response lines are not parallel (crossing)
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

13. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
50%
Used to create frequency distribution tally sheets
No -- the variation also has to be random and "expected."
= yij - y(bar)i --> value minus sum of that treatment (of row)

14. FMEA
3.4 (assuming 1.5 sigma shift in the mean)
Blame.
It looks to minimize the probability of a failure - or to minimize its effects
The manager in charge of a process being improved in a Six Sigma project.

15. To what does the Six in Six Sigma relate?
0.9^3 or 72.9%
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.
Mean time to replacement.
The target number of standard deviations from the mean for specifications.

16. What does DMAIC stand for?
Define - measure - analyze - improve - control.
p-bar - the long-run percent defective.
Speed - courtesy - competence - and ease of repair.
Stratify a particular defect type according to logical criteria

17. Advantages of DOE
A brainstorming tool that shows the connections between ideas.
Outside.
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
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

18. In a regression - what does the coefficient of the intercept tell you
Linearity - normality - homoscedasticity - independence.
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
Rapid improvement process.
What the value of the dependent variable is when the independent variable is zero.

19. Cause and Effect Diagrams
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The Japanese national quality award.
Method developed by Ishikawa to graphically display the causes of any given problem
Lean is waste reduction - Six Sigma is variation reduction.

20. What is the formula for standard deviation?
Attribute.
Through producer/consumer negotiation.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
=sqrt(Σ(x-x-bar)^2)/(n-1))

21. What do you do when a process is out of control?
F_alpha - df(tr) - df (error)
Stratify a particular defect type according to logical criteria
Look for the assignable cause of non-random variation.
Define - measure - analyze - design - verify.

22. Process occurance ranking
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Through producer/consumer negotiation.
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).
No -- only if the process is also capable.

23. What is written on the "spines" of a fishbone diagram?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Causes that lead to a particular effect.
Studying firms with the best performance in a particular area.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

24. Why do you need two control charts for variables SPC?
Prevention and appraisal costs are balanced against internal and external failure.
Because the mean and standard deviation are independent of each other.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
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:

25. What happens to control limits on an SPC chart when sample size is increased?
Method developed by Ishikawa to graphically display the causes of any given problem
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
They move closer to the center line.
10 if Almost impossible to detect

26. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Fewer good units to sell - increased variable cost/unit.
Rapid improvement process.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Outside.

27. Define product reliability.
68%
50%
Mean time to failure.
Concluding there has been an effect/change when there has not.

28. F value
Concluding there has not been an effect/change when there has.
Attribute.
F_alpha - df(tr) - df (error)
Kaoru Ishikawa.

29. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Conformance to specifications.
Inventory = throughput x flow time.

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

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31. What is DMADV?
Define - measure - analyze - design - verify.
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
10 for Hazardous without warning 1 for none
A tool that shows performance along key dimensions all at once.

32. What does the abbreviation LCL stand for?
No -- if it is not the same - it can only be worse!
Through producer/consumer negotiation.
Lower control limit.
They move closer to the center line.

33. Define aesthetic quality.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Pleasing to the senses.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

34. Disadvantages of DOE

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35. One factor at a time (OFAT)
Sort - Set in Order - Shine - Standardize - Sustain
Rapid improvement process.
Hold all input variables constant except one. Observe the response as you vary the single input.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

36. If a Cp shows that a process is not capable - should you calculate Cpk?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The gap between what management thinks customers want and what customers really want.
Fishbone - cause-and-effect diagram.
No -- if it is not the same - it can only be worse!

37. In a regression - what does R-square tell you?
=sqrt((p*(1-p)/n)
Concluding there has been an effect/change when there has not.
The gap between specifications and how service is performed.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

38. What are the four perspectives of the Balanced Scorecard?
An assertion or conjecture concerning one or more populations
The primary operating characteristics of a product.
The gap between what is promised and what is delivered.
Financial - customer - internal process - innovation and learning.

39. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
Controlling quality at the source.
100%
Studying firms with the best performance in a particular area.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

40. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Financial - customer - internal process - innovation and learning.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Lean (or JIT).
The Japanese national quality award.

41. What is Type II Error?
It looks to minimize the probability of a failure - or to minimize its effects
Concluding there has not been an effect/change when there has.
Fractional factorial designs (orthogonal arrays)
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

42. 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.
A diagram that shows the relationships between activities in a project network.
Initiated before or at design concept finalization
A tool that shows where there is waste in a process.

43. Presence of interaction effect
Studying firms with the best performance in a particular area.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Pleasing to the senses.
Prevention and appraisal costs are balanced against internal and external failure.

44. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Used to create frequency distribution tally sheets
=sqrt((p*(1-p)/n)
Variable.
The gap between what is promised and what is delivered.

45. What is the Deming Prize?
Workers - machines - materials.
The Japanese national quality award.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
= yij - y(bar)i --> value minus sum of that treatment (of row)

46. What does the abbreviation UCL stand for?
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
A brainstorming tool that shows the connections between ideas.
To do a capability study for a non-centered process.
Upper control limit.

47. What is muda
Upper control limit.
= 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
F_alpha - df(tr) - df (error)
Waste.

48. DFMEA
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
Variable.
No -- the variation also has to be random and "expected."
Initiated before or at design concept finalization

49. Define features.
Someone who is consistently against virtually everything.
Scrap - rework - retest - downtime - yield losses - disposition costs.
The secondary characteristics of a product; "bells and whistles."
Taguchi

50. What is the center line of a p-chart?
Actual drawings - layouts - maps - etc which show where a defect occurs
Variable.
p-bar - the long-run percent defective.
Kaoru Ishikawa.