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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 is a Gage R&R?
Defects Per Million Opportunities
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 obtain a certain desirable outcome from the process
The target number of standard deviations from the mean for specifications.

2. What is the difference between Lean and Six Sigma?
99.73%
50%
Central Limit Theorem
Lean is waste reduction - Six Sigma is variation reduction.

3. A process is operating "in control." Does this mean the customer's requirements are met?
No -- only if the process is also capable.
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
A tool that shows the physical flows through a space.
Fractional factorial designs (orthogonal arrays)

4. Define benchmarking.
Studying firms with the best performance in a particular area.
Before production starts
100%
QFD

5. Which type of SPC measurement is more precise - variable or attribute?
Define - measure - analyze - improve - control.
The ratio of outputs to inputs; 1-scrap.
Variable.
Mistake-proofing.

6. What is process capability?
F_alpha - df(tr) - df (error)
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
The ability of a process to consistently meet customer specifications.
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

7. What does Crosby say about benchmarking?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Consumer risk.
Studying firms with the best performance in a particular area.
Blame.

8. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
68%
No -- only if the process is also capable.
Lower skill requirements - faster - less chance for error.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

9. Presence of interaction effect
Upper control limit.
Lower skill requirements - faster - less chance for error.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
= 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

10. List two components of external failure.
Inventory = throughput x flow time.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Lean (or JIT).
A tool that shows the physical flows through a space.

11. Who developed the fishbone diagram?
Speed - courtesy - competence - and ease of repair.
Workers - machines - materials.
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
Kaoru Ishikawa.

12. Creating a Run Chart
The gap between what management thinks customers want and what customers really want.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Technical quality is the "what" of the service; functional quality is the "how."

13. Simple Regression Analysis (one factor regression model)
Observed variation in response is caused by the input
= 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
Lean (or JIT).
The primary operating characteristics of a product.

14. What is the formula for standard deviation?
Workers - machines - materials.
Speed - courtesy - competence - and ease of repair.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Used to create frequency distribution tally sheets

15. FMEA
X-bar-bar
No -- if it is not the same - it can only be worse!
It looks to minimize the probability of a failure - or to minimize its effects
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:

16. In the Service Quality Gap Model - what is Gap 2?
Lean is waste reduction - Six Sigma is variation reduction.
The gap between what management thinks customers want and the process specifications.
False - because each machine will have different natural tolerances.
=sqrt((p*(1-p)/n)

17. What is a network diagram?
A diagram that shows the relationships between activities in a project network.
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
Deming.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

18. In a regression - what does the coefficient of the intercept tell you
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
What the value of the dependent variable is when the independent variable is zero.
Studying firms with the best performance in a particular area.
The manager in charge of a process being improved in a Six Sigma project.

19. What is a CAVE man?
Fishbone - cause-and-effect diagram.
Someone who is consistently against virtually everything.
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).
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

20. Residual
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
To be a member of a Six Sigma project team.
The target number of standard deviations from the mean for specifications.
The number of standard deviations some value is from the mean.

21. Define features.
Prevention - appraisal - internal failure - external failure.
Concluding there has not been an effect/change when there has.
Kaoru Ishikawa.
The secondary characteristics of a product; "bells and whistles."

22. In the Service Quality Gap Model - what is Gap 5?
Because the mean and standard deviation are independent of each other.
Not necessarily.
The gap between what customers expect and the service they receive.
Causes that lead to a particular effect.

23. Process occurance ranking
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
No -- if it is not the same - it can only be worse!
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

24. Advantages of DOE
A tool that shows the physical flows through a space.
Concluding there has not been an effect/change when there has.
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
Actual drawings - layouts - maps - etc which show where a defect occurs

25. What is a dashboard?
Is what induces the failure
A tool that shows performance along key dimensions all at once.
Look for the assignable cause of non-random variation.
Mean time to failure.

26. What quality tool formally incorporates the voice of the customer?
Defects Per Million Opportunities
Lower control limit.
QFD
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

27. How does Juran define quality?
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
To obtain a certain desirable outcome from the process
Fitness for use.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

28. What is poka yoke?
Define - measure - analyze - design - verify.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Mistake-proofing.
To monitor a process when measurement by attribute is used.

29. What quality guru emphasizes management as a system?
The number of standard deviations some value is from the mean.
Deming.
Define - measure - analyze - improve - control.
The Japanese national quality award.

30. What is DMADV?
Sampling for SPC is done real time.
A brainstorming tool that shows the connections between ideas.
Define - measure - analyze - design - verify.
Observed variation in response is caused by the input

31. Process check sheets
QFD
Used to create frequency distribution tally sheets
Reliability - Assurance - Responsiveness - Tangibles - Empathy
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

32. What type of risk is associated with Type II Error?
Consumer risk.
QFD
Producer risk.
Prevention - appraisal - internal failure - external failure.

33. Affinity Diagrams
No -- only if the process is also capable.
5%
Organize ideas into meaningful categories by recognizing their underlying similarity
Represents the behavior of a process

34. What graphical tool is used to show the relationship between two numerical variables?
To obtain a certain desirable outcome from the process
Shows the temporal flow of activities in a project network.
The Japanese national quality award.
A scatterplot.

35. What is the Baldrige Award?
The US national quality award.
The degree to which a product meets pre-established standards.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

36. Histogram by Hand
The gap between what management thinks customers want and the process specifications.
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
Is the way in which the failure is manifested.
Sampling for SPC is done real time.

37. Based on what principal can we use the normal distribution assumptions for SPC?
The cycle time required to meet demand.
Shows the temporal flow of activities in a project network.
Central Limit Theorem
Sampling for SPC is done real time.

38. List Garvin's eight dimensions of product quality.
The gap between what management thinks customers want and what customers really want.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Studying firms with the best performance in a particular area.

39. What are the four categories of costs in Juran's framework?
Fractional factorial designs (orthogonal arrays)
Prevention - appraisal - internal failure - external failure.
X-bar-bar
Not necessarily.

40. ANOVA

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41. Residual(eij)
= yij - y(bar)i --> value minus sum of that treatment (of row)
Hold all input variables constant except one. Observe the response as you vary the single input.
A descending order-sorted bar chart with a cumulative percentage line.
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

42. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Financial - customer - internal process - innovation and learning.
Attribute
It's good -- but it's still out of control!
The US national quality award.

43. What is the formula for the standard deviation of a proportion?
A time series plot.
=sqrt((p*(1-p)/n)
Upper control limit.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

44. What does the abbreviation UCL stand for?
Hold all input variables constant except one. Observe the response as you vary the single input.
Mean time to failure.
Upper control limit.
A time series plot.

45. If a Cp shows that a process is not capable - should you calculate Cpk?
Initiated before or at design concept finalization
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
No -- if it is not the same - it can only be worse!
Someone who is consistently against virtually everything.

46. What is a run chart?
A time series plot.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Organize ideas into meaningful categories by recognizing their underlying similarity
Lower control limit.

47. What does DMAIC stand for?
Define - measure - analyze - improve - control.
Linearity - normality - homoscedasticity - independence.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
No -- if it is not the same - it can only be worse!

48. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Sampling for SPC is done real time.
Financial - customer - internal process - innovation and learning.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Organize ideas into meaningful categories by recognizing their underlying similarity

49. What is an affinity diagram?
Speed - courtesy - competence - and ease of repair.
50%
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
A brainstorming tool that shows the connections between ideas.

50. Define yield.
50%
The ratio of outputs to inputs; 1-scrap.
Mean time to replacement.
Studying firms with the best performance in a particular area.