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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. One factor at a time (OFAT)
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Observed variation in response is caused by the input
A diagram that shows the relationships between activities in a project network.
95%

2. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
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
To mentor/coach (and sometimes train) black belts.
Conformance to specifications.
It looks to minimize the probability of a failure - or to minimize its effects

3. Defect location check sheets
Different types of defects are listed (used for Pareto chart)
Actual drawings - layouts - maps - etc which show where a defect occurs
The primary operating characteristics of a product.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

4. Define product reliability.
Mean time to failure.
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.
50%
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:

5. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
68%
0.9^3 or 72.9%
Causes that lead to a particular effect.
False - because each machine will have different natural tolerances.

6. Cause and Effect Diagrams
Used to create frequency distribution tally sheets
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
To monitor a process when measurement by variables is used.
Method developed by Ishikawa to graphically display the causes of any given problem

7. List two components of internal failure.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
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
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Scrap - rework - retest - downtime - yield losses - disposition costs.

8. To what does the Six in Six Sigma relate?
The target number of standard deviations from the mean for specifications.
3.4 (assuming 1.5 sigma shift in the mean)
95%
Fitness for use.

9. DOE
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Taguchi
Large enough to find two of the attribute - on average.

10. What is the formula for the standard deviation of a proportion?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The target number of standard deviations from the mean for specifications.
=sqrt((p*(1-p)/n)
The gap between what management thinks customers want and what customers really want.

11. Does it ever make sense to accept a job when a process is incapable?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Rapid improvement process.
To obtain a certain desirable outcome from the process
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

12. What are two other names for an Ishikawa diagram?
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
Mean time to failure.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Fishbone - cause-and-effect diagram.

13. What is DMADV?
A tool that shows performance along key dimensions all at once.
Define - measure - analyze - design - verify.
Outside.
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

14. What is a network diagram?
A diagram that shows the relationships between activities in a project network.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
To be a member of a Six Sigma project team.
The number of standard deviations some value is from the mean.

15. What is an affinity diagram?
A descending order-sorted bar chart with a cumulative percentage line.
To do a capability study for a non-centered process.
Represents the behavior of a process
A brainstorming tool that shows the connections between ideas.

16. Define features.
Fitness for use.
The secondary characteristics of a product; "bells and whistles."
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
To obtain a certain desirable outcome from the process

17. What is written on the "spines" of a fishbone diagram?
Is the way in which the failure is manifested.
Mistake-proofing.
Causes that lead to a particular effect.
100%

18. Based on what principal can we use the normal distribution assumptions for SPC?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Central Limit Theorem
Hold all input variables constant except one. Observe the response as you vary the single input.
To obtain a certain desirable outcome from the process

19. 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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20. What is a CAVE man?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
A diagram that shows the relationships between activities in a project network.
Someone who is consistently against virtually everything.
Concluding there has not been an effect/change when there has.

21. If a three-stage process has 90% yields at each stage - what is the overall yield?
Defects Per Million Opportunities
Prevention - appraisal - internal failure - external failure.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
0.9^3 or 72.9%

22. Stratified defect check sheets
Organize ideas into meaningful categories by recognizing their underlying similarity
Stratify a particular defect type according to logical criteria
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The secondary characteristics of a product; "bells and whistles."

23. In the Service Quality Gap Model - what is Gap 1?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The gap between what management thinks customers want and what customers really want.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

24. Failure cause
Is the consequence of the failure.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
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
Is what induces the failure

25. Residual
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Not necessarily.
Inventory = throughput x flow time.

26. If you can only collect categorical data - what type of SPC charting can you do?
A descending order-sorted bar chart with a cumulative percentage line.
A tool that shows performance along key dimensions all at once.
Attribute.
Fractional factorial designs (orthogonal arrays)

27. What size should samples be for attribute SPC?
Large enough to find two of the attribute - on average.
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
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
An assertion or conjecture concerning one or more populations

28. What is a run chart?
A time series plot.
95%
Is what induces the failure
Studying firms with the best performance in a particular area.

29. Disadvantages of DOE

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30. What percentage of a normal distribution lies above the mean?
50%
If the Response vs. Levels graph if the response lines are not parallel (crossing)
The cycle time required to meet demand.
A random variable that summarizes the information from the sample(s).

31. What is Kaizen?
3.4 (assuming 1.5 sigma shift in the mean)
Rapid improvement process.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Define - measure - analyze - improve - control.

32. What is the role of a green belt?
Before production starts
Critical to quality.
To be a member of a Six Sigma project team.
Supplier - input - process - output - customer.

33. What is a Pareto chart?
The ratio of outputs to inputs; 1-scrap.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The gap between what is promised and what is delivered.
A descending order-sorted bar chart with a cumulative percentage line.

34. What are the Five Dimensions of Service Quality?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
=sqrt(Σ(x-x-bar)^2)/(n-1))
Can't tell without a Range chart.
Blame.

35. Affinity Diagrams
Brand image.
Studying firms with the best performance in a particular area.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

36. What is the role of a black belt?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Rapid improvement process.
To manage the Six Sigma project.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

37. What is the center line of an X-bar chart?
Through producer/consumer negotiation.
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:
Producer risk.
X-bar-bar

38. PFMEA
A tool that shows the physical flows through a space.
Causes that lead to a particular effect.
95%
Before production starts

39. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
The number of standard deviations some value is from the mean.
No -- if it is not the same - it can only be worse!
5%
Used to create frequency distribution tally sheets

40. Affinity Diagrams
5%
To manage the Six Sigma project.
Organize ideas into meaningful categories by recognizing their underlying similarity
Kaoru Ishikawa.

41. What does SIPOC stand for?
Workers - machines - materials.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Lower skill requirements - faster - less chance for error.
Supplier - input - process - output - customer.

42. What is the Baldrige Award?
The US national quality award.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
No -- only if the process is also capable.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

43. Failure Mode
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Is the way in which the failure is manifested.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
False - because each machine will have different natural tolerances.

44. What does DMAIC stand for?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
A time series plot.
Represents the behavior of a process
Define - measure - analyze - improve - control.

45. How does Juran define quality?
Fitness for use.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
To be a member of a Six Sigma project team.
3.4 (assuming 1.5 sigma shift in the mean)

46. In the Service Quality Gap Model - what is Gap 5?
The gap between what is promised and what is delivered.
100%
The gap between what customers expect and the service they receive.
Failure Modes and Effects Analysis

47. For what is an x-bar chart used?
Fishbone - cause-and-effect diagram.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
The gap between what management thinks customers want and the process specifications.
To monitor a process when measurement by variables is used.

48. Who developed the fishbone diagram?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
The gap between what is promised and what is delivered.
Kaoru Ishikawa.
Mistake-proofing.

49. If a Cp shows that a process is not capable - should you calculate Cpk?
Lower control limit.
Concluding there has been an effect/change when there has not.
The gap between what management thinks customers want and the process specifications.
No -- if it is not the same - it can only be worse!

50. What are the four perspectives of the Balanced Scorecard?
The ability of a process to consistently meet customer specifications.
Financial - customer - internal process - innovation and learning.
=sqrt(Σ(x-x-bar)^2)/(n-1))
The primary operating characteristics of a product.