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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 Pareto chart?
Concluding there has not been an effect/change when there has.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
A descending order-sorted bar chart with a cumulative percentage line.
The gap between what is promised and what is delivered.

2. Define features.
The manager in charge of a process being improved in a Six Sigma project.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Before production starts
The secondary characteristics of a product; "bells and whistles."

3. Process occurance ranking
Mean time to replacement.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
An assertion or conjecture concerning one or more populations
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

4. Risk Priority Number RPN
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Rapid improvement process.
Central Limit Theorem
Mean time to failure.

5. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Concluding there has not been an effect/change when there has.
Mean time to failure.
No -- if it is not the same - it can only be worse!
Lean (or JIT).

6. What is CTQ?
X-bar-bar
A tool that shows the physical flows through a space.
Critical to quality.
99.73%

7. What is DMADV?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The primary operating characteristics of a product.
Define - measure - analyze - design - verify.
The US national quality award.

8. There are two milling machines in the shop. Data has been collected on one to compute control limits for both. This is acceptable SPC practice - true or false and why?
95%
They move closer to the center line.
False - because each machine will have different natural tolerances.
The gap between what management thinks customers want and the process specifications.

9. What do you do when a process is out of control?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
The ability of a process to consistently meet customer specifications.
Look for the assignable cause of non-random variation.
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

10. Name the structure associated with Quality Function Deployment.
The US national quality award.
The degree to which a product meets pre-established standards.
To do a capability study for a non-centered process.
The House of Quality.

11. Design of Experiments (DOE) approach
Observed variation in response is caused by the input
Inventory = throughput x flow time.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The manager in charge of a process being improved in a Six Sigma project.

12. What is the difference between Lean and Six Sigma?
Failure Modes and Effects Analysis
Lean is waste reduction - Six Sigma is variation reduction.
Rapid improvement process.
Not necessarily.

13. What is a Gage R&R?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
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).
Lean (or JIT).
Inventory = throughput x flow time.

14. What graphical tool is used to show the relationship between two numerical variables?
A scatterplot.
Prevention - appraisal - internal failure - external failure.
Represents the behavior of a process
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

15. FMEA
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
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
68%
Reliability - Assurance - Responsiveness - Tangibles - Empathy

16. List two components of internal failure.
Causes that lead to a particular effect.
A tool that shows the physical flows through a space.
Deming.
Scrap - rework - retest - downtime - yield losses - disposition costs.

17. Define conformance quality.
Method developed by Ishikawa to graphically display the causes of any given problem
The degree to which a product meets pre-established standards.
A tool that shows performance along key dimensions all at once.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

18. Presence of interaction effect
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Attribute.
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:
Is the way in which the failure is manifested.

19. What are the four categories of costs in Juran's framework?
Variable.
The cycle time required to meet demand.
Prevention - appraisal - internal failure - external failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.

20. When is Cpk used?
A brainstorming tool that shows the connections between ideas.
Variable.
To do a capability study for a non-centered process.
Studying firms with the best performance in a particular area.

21. Non-random patterns (Run Charts)
X-bar-bar
A tool that shows performance along key dimensions all at once.
Used to create frequency distribution tally sheets
Shifts - Trends - Repeating patterns - Correlation with known events

22. What is Kaizen?
To do a capability study for a non-centered process.
Defects Per Million Opportunities
The House of Quality.
Rapid improvement process.

23. What is the Baldrige Award?
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
A time series plot.
Because the mean and standard deviation are independent of each other.
The US national quality award.

24. Uses of regression
Look for the assignable cause of non-random variation.
Waste.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The ability of a process to consistently meet customer specifications.

25. What quality tool formally incorporates the voice of the customer?
QFD
Lower control limit.
95%
X-bar-bar

26. Uses of regression - Control
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Assigns scores to weighted criteria for each project under consideration.
To obtain a certain desirable outcome from the process
The Japanese national quality award.

27. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
The ability of a process to consistently meet customer specifications.
Blame.
Variable.
Conformance to specifications.

28. Advantages of DOE
Shows the temporal flow of activities in a project network.
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 be a member of a Six Sigma project team.
Financial - customer - internal process - innovation and learning.

29. Complete this quality phrase: 'Fix the process - not the _____.'
The primary operating characteristics of a product.
Producer risk.
Prevention - appraisal - internal failure - external failure.
Blame.

30. What is a run chart?
An assertion or conjecture concerning one or more populations
Controlling quality at the source.
5%
A time series plot.

31. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Is what induces the failure
Sampling for SPC is done real time.
Central Limit Theorem
Can't tell without a Range chart.

32. In the Service Quality Gap Model - what is Gap 5?
=sqrt(Σ(x-x-bar)^2)/(n-1))
10 for Hazardous without warning 1 for none
The gap between what customers expect and the service they receive.
Brand image.

33. What is Value Stream Mapping?
Is the consequence of the failure.
To monitor a process when measurement by attribute is used.
A tool that shows where there is waste in a process.
Defects Per Million Opportunities

34. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Actual drawings - layouts - maps - etc which show where a defect occurs
No -- the variation also has to be random and "expected."
The degree to which a product meets pre-established standards.
Through producer/consumer negotiation.

35. In the Service Quality Gap Model - what is Gap 1?
Deming.
The gap between what management thinks customers want and what customers really want.
To monitor a process when measurement by attribute is used.
Mean time to replacement.

36. What type of risk is associated with Type 1 Error?
A random variable that summarizes the information from the sample(s).
Attribute
A diagram that shows the relationships between activities in a project network.
Producer risk.

37. Definition of Interaction
Inventory = throughput x flow time.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
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.

38. What is the center line of an X-bar chart?
Attribute.
Defects Per Million Opportunities
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
X-bar-bar

39. The Test Statistic (TS)
A random variable that summarizes the information from the sample(s).
A scatterplot.
QFD
0.9^3 or 72.9%

40. Affinity Diagrams
Lean (or JIT).
Before production starts
Organize ideas into meaningful categories by recognizing their underlying similarity
= yij - y(bar)i --> value minus sum of that treatment (of row)

41. Define benchmarking.
Prevention and appraisal costs are balanced against internal and external failure.
Kaoru Ishikawa.
Studying firms with the best performance in a particular area.
A tool that shows the physical flows through a space.

42. Taguchi's experimental designs are of this type.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Supplier - input - process - output - customer.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Fractional factorial designs (orthogonal arrays)

43. Define durability.
Kaoru Ishikawa.
Mean time to replacement.
Prevention - appraisal - internal failure - external failure.
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

44. What is Little's Law?
Fractional factorial designs (orthogonal arrays)
Attribute
X-bar-bar
Inventory = throughput x flow time.

45. Simple Regression Analysis (one factor regression model)
The gap between what is promised and what is delivered.
= 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 if Almost impossible to detect
Variable.

46. ANOVA

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47. Which type of SPC measurement is more precise - variable or attribute?
Is the way in which the failure is manifested.
The ratio of outputs to inputs; 1-scrap.
Blame.
Variable.

48. Who developed the fishbone diagram?
A random variable that summarizes the information from the sample(s).
Defects Per Million Opportunities
Kaoru Ishikawa.
Prevention - appraisal - internal failure - external failure.

49. What is DPMO?
QFD
Variable.
Fitness for use.
Defects Per Million Opportunities

50. What is a dashboard?
A tool that shows performance along key dimensions all at once.
Before production starts
Mean time to replacement.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions