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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 categories of costs in Juran's framework?
Mean time to failure.
Prevention - appraisal - internal failure - external failure.
5%
Conformance to specifications.

2. Daniel Test
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:
Define - measure - analyze - design - verify.
10 if Almost impossible to detect
Producer risk.

3. What is the role of a master black belt?
To mentor/coach (and sometimes train) black belts.
Fitness for use.
Inventory = throughput x flow time.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

4. Histogram by Hand
Producer risk.
The House of Quality.
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
The gap between what is promised and what is delivered.

5. What graphical tool is used to show the relationship between two numerical variables?
A scatterplot.
Large enough to find two of the attribute - on average.
To do a capability study for a non-centered process.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

6. What is Jidoka?
Controlling quality at the source.
A time series plot.
Lower skill requirements - faster - less chance for error.
The gap between what management thinks customers want and what customers really want.

7. Define features.
Sampling for SPC is done real time.
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).
The secondary characteristics of a product; "bells and whistles."
Is the way in which the failure is manifested.

8. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Conformance to specifications.
It's good -- but it's still out of control!
Define - measure - analyze - design - verify.
Supplier - input - process - output - customer.

9. What is a histogram?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Before production starts
Used to create frequency distribution tally sheets

10. What quality guru emphasizes management as a system?
Deming.
The House of Quality.
68%
= yij - y(bar)i --> value minus sum of that treatment (of row)

11. Regression
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Rapid improvement process.
Studying firms with the best performance in a particular area.
Represents the behavior of a process

12. FMEA
A brainstorming tool that shows the connections between ideas.
A tool that shows performance along key dimensions all at once.
The degree to which a product meets pre-established standards.
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

13. What are the 5 Ss?
10 for Hazardous without warning 1 for none
Controlling quality at the source.
Sort - Set in Order - Shine - Standardize - Sustain
The US national quality award.

14. What quality tool formally incorporates the voice of the customer?
QFD
=sqrt(Σ(x-x-bar)^2)/(n-1))
Method developed by Ishikawa to graphically display the causes of any given problem
Large enough to find two of the attribute - on average.

15. List two components of internal failure.
Supplier - input - process - output - customer.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Sampling for SPC is done real time.
To obtain a certain desirable outcome from the process

16. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Producer risk.
To do a capability study for a non-centered process.
95%

17. Process occurance ranking
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
The degree to which a product meets pre-established standards.
QFD
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

18. Cause and Effect Diagrams
Workers - machines - materials.
A random variable that summarizes the information from the sample(s).
The House of Quality.
Method developed by Ishikawa to graphically display the causes of any given problem

19. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Assigns scores to weighted criteria for each project under consideration.
Critical to quality.
Attribute
An assertion or conjecture concerning one or more populations

20. Who first studied randomness in industrial processes
An assertion or conjecture concerning one or more populations
The manager in charge of a process being improved in a Six Sigma project.
Walter A. Shewhart
Workers - machines - materials.

21. In a regression - what does the standard error of the estimate tell you?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Variable.
To be a member of a Six Sigma project team.
Is the consequence of the failure.

22. 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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23. Define conformance quality.
The degree to which a product meets pre-established standards.
The Japanese national quality award.
Define - measure - analyze - design - verify.
A brainstorming tool that shows the connections between ideas.

24. Affinity Diagrams
The gap between what is promised and what is delivered.
The gap between what customers expect and the service they receive.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Controlling quality at the source.

25. What does a project prioritization matrix do?
Assigns scores to weighted criteria for each project under consideration.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
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
Someone who is consistently against virtually everything.

26. Taguchi's experimental designs are of this type.
Fractional factorial designs (orthogonal arrays)
Mistake-proofing.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

27. Failure cause
Inventory = throughput x flow time.
The gap between what is promised and what is delivered.
Is what induces the failure
A diagram that shows the relationships between activities in a project network.

28. How does Juran define quality?
Concluding there has not been an effect/change when there has.
Fitness for use.
Stratify a particular defect type according to logical criteria
They move closer to the center line.

29. In the Service Quality Gap Model - what is Gap 4?
Scrap - rework - retest - downtime - yield losses - disposition costs.
The gap between what is promised and what is delivered.
The secondary characteristics of a product; "bells and whistles."
To do a capability study for a non-centered process.

30. What happens to control limits on an SPC chart when sample size is increased?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
They move closer to the center line.
Lean (or JIT).
A random variable that summarizes the information from the sample(s).

31. Based on what principal can we use the normal distribution assumptions for SPC?
68%
Lean is waste reduction - Six Sigma is variation reduction.
Studying firms with the best performance in a particular area.
Central Limit Theorem

32. Pareto Analysis
5%
0.9^3 or 72.9%
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
To monitor a process when measurement by variables is used.

33. Who developed the fishbone diagram?
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
Technical quality is the "what" of the service; functional quality is the "how."
Scrap - rework - retest - downtime - yield losses - disposition costs.
Kaoru Ishikawa.

34. Definition of Interaction
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
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Upper control limit.
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

35. Residual
Initiated before or at design concept finalization
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Define - measure - analyze - improve - control.
10 if Almost impossible to detect

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

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37. What does SIPOC stand for?
The House of Quality.
Studying firms with the best performance in a particular area.
Supplier - input - process - output - customer.
5%

38. Failure Mode
Is the way in which the failure is manifested.
Waste.
Mistake-proofing.
Fitness for use.

39. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Fractional factorial designs (orthogonal arrays)
100%
No -- only if the process is also capable.

40. F value
If the Response vs. Levels graph if the response lines are not parallel (crossing)
F_alpha - df(tr) - df (error)
The gap between what management thinks customers want and the process specifications.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

41. Explain the difference between technical and functional service quality.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
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).
To manage the Six Sigma project.
Technical quality is the "what" of the service; functional quality is the "how."

42. What is an affinity diagram?
A tool that shows where there is waste in a process.
A brainstorming tool that shows the connections between ideas.
No -- the variation also has to be random and "expected."
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

43. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
99.73%
Mean time to replacement.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

44. When yields decrease - what are the two effects on contribution?
Linearity - normality - homoscedasticity - independence.
The gap between what customers expect and the service they receive.
QFD
Fewer good units to sell - increased variable cost/unit.

45. Define perceived quality (Garvin's framework).
A scatterplot.
Brand image.
Waste.
68%

46. List two components of external failure.
To monitor a process when measurement by attribute is used.
Because the mean and standard deviation are independent of each other.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
0.9^3 or 72.9%

47. In the Service Quality Gap Model - what is Gap 3?
The gap between what is promised and what is delivered.
The gap between specifications and how service is performed.
Scrap - rework - retest - downtime - yield losses - disposition costs.
F_alpha - df(tr) - df (error)

48. Defect location check sheets
Prevention - appraisal - internal failure - external failure.
Actual drawings - layouts - maps - etc which show where a defect occurs
Lower control limit.
Large enough to find two of the attribute - on average.

49. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
Financial - customer - internal process - innovation and learning.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Outside.

50. Manual Test for Nomality
Waste.
Is the consequence of the failure.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper