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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 does Crosby say about benchmarking?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Concluding there has been an effect/change when there has not.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Brand image.

2. TWO-DIMENTIONAL SCATTER PLOT
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
No -- the variation also has to be random and "expected."

3. What is Kaizen?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Blame.
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
Rapid improvement process.

4. ANOVA

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5. What is the formula for the standard deviation of a proportion?
The cycle time required to meet demand.
Initiated before or at design concept finalization
A random variable that summarizes the information from the sample(s).
=sqrt((p*(1-p)/n)

6. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
99.73%
Controlling quality at the source.
A random variable that summarizes the information from the sample(s).

7. What is the role of a green belt?
To be a member of a Six Sigma project team.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
A tool that shows performance along key dimensions all at once.
68%

8. If a three-stage process has 90% yields at each stage - what is the overall yield?
Upper control limit.
0.9^3 or 72.9%
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
=sqrt((p*(1-p)/n)

9. Pareto Analysis
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
Technical quality is the "what" of the service; functional quality is the "how."
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Speed - courtesy - competence - and ease of repair.

10. In the Service Quality Gap Model - what is Gap 1?
Failure Modes and Effects Analysis
A random variable that summarizes the information from the sample(s).
The gap between what management thinks customers want and what customers really want.
50%

11. Process occurance ranking
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.
Inventory = throughput x flow time.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Producer risk.

12. What quality guru emphasizes management as a system?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The gap between what customers expect and the service they receive.
Deming.
The ability of a process to consistently meet customer specifications.

13. What is DPMO?
Defects Per Million Opportunities
The gap between what management thinks customers want and what customers really want.
To obtain a certain desirable outcome from the process
Causes that lead to a particular effect.

14. F value
F_alpha - df(tr) - df (error)
The secondary characteristics of a product; "bells and whistles."
=sqrt((p*(1-p)/n)
p-bar - the long-run percent defective.

15. What is Little's Law?
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).
What the value of the dependent variable is when the independent variable is zero.
Inventory = throughput x flow time.
Not necessarily.

16. When yields decrease - what are the two effects on contribution?
It's good -- but it's still out of control!
Fewer good units to sell - increased variable cost/unit.
Taguchi
The gap between what management thinks customers want and what customers really want.

17. Failure cause
Is what induces the failure
Walter A. Shewhart
Lean (or JIT).
No -- the variation also has to be random and "expected."

18. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Failure Modes and Effects Analysis
Variable.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

19. Define aesthetic quality.
Brand image.
The House of Quality.
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
Pleasing to the senses.

20. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Outside.
Prevention - appraisal - internal failure - external failure.
It's good -- but it's still out of control!
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

21. Complete this quality phrase: 'Fix the process - not the _____.'
Prevention and appraisal costs are balanced against internal and external failure.
Blame.
Sort - Set in Order - Shine - Standardize - Sustain
Prevention - appraisal - internal failure - external failure.

22. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Taguchi
Concluding there has been an effect/change when there has not.
Attribute
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.

23. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Prevention and appraisal costs are balanced against internal and external failure.
Conformance to specifications.
Speed - courtesy - competence - and ease of repair.
Defects Per Million Opportunities

24. What are the four categories of costs in Juran's framework?
Prevention - appraisal - internal failure - external failure.
To obtain a certain desirable outcome from the process
False - because each machine will have different natural tolerances.
A brainstorming tool that shows the connections between ideas.

25. Process check sheets
=sqrt((p*(1-p)/n)
Large enough to find two of the attribute - on average.
Used to create frequency distribution tally sheets
= yij - y(bar)i --> value minus sum of that treatment (of row)

26. Define serviceability.
A diagram that shows the relationships between activities in a project network.
The primary operating characteristics of a product.
A tool that shows performance along key dimensions all at once.
Speed - courtesy - competence - and ease of repair.

27. What are the four perspectives of the Balanced Scorecard?
A time series plot.
QFD
Financial - customer - internal process - innovation and learning.
The number of standard deviations some value is from the mean.

28. Risk Priority Number RPN
The gap between what customers expect and the service they receive.
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 scatterplot.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

29. Define features.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
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 secondary characteristics of a product; "bells and whistles."

30. For what is an x-bar chart used?
To do a capability study for a non-centered process.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Supplier - input - process - output - customer.
To monitor a process when measurement by variables is used.

31. In a regression - what does R-square tell you?
Financial - customer - internal process - innovation and learning.
Critical to quality.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Actual drawings - layouts - maps - etc which show where a defect occurs

32. What are the three main categories of assignable cause?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
99.73%
Workers - machines - materials.
Represents the behavior of a process

33. Disadvantages of DOE

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34. Definition of Interaction
Attribute
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
To mentor/coach (and sometimes train) black belts.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

35. What is FMEA?
Failure Modes and Effects Analysis
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
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

36. What is a run chart?
A time series plot.
Is the consequence of the failure.
To obtain a certain desirable outcome from the process
Deming.

37. What percentage of a normal distribution lies above the mean?
Lean (or JIT).
50%
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 mentor/coach (and sometimes train) black belts.

38. Advantages of DOE
The Japanese national quality award.
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).
It looks to minimize the probability of a failure - or to minimize its effects
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

39. List two components of prevention cost.
Represents the behavior of a process
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Sampling for SPC is done real time.
It looks to minimize the probability of a failure - or to minimize its effects

40. What is the center line of a p-chart?
Financial - customer - internal process - innovation and learning.
p-bar - the long-run percent defective.
A time series plot.
Used to create frequency distribution tally sheets

41. Test for Independence
To do a capability study for a non-centered process.
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
Fewer good units to sell - increased variable cost/unit.
Hold all input variables constant except one. Observe the response as you vary the single input.

42. Defect check sheets
Different types of defects are listed (used for Pareto chart)
Financial - customer - internal process - innovation and learning.
Concluding there has not been an effect/change when there has.
Central Limit Theorem

43. Regression Analysis
The gap between what management thinks customers want and the process specifications.
Outside.
Taguchi
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

44. Define conformance quality.
The degree to which a product meets pre-established standards.
3.4 (assuming 1.5 sigma shift in the mean)
Supplier - input - process - output - customer.
Because the mean and standard deviation are independent of each other.

45. Your production process meets customer specifications. Is your process in control?
Not necessarily.
The target number of standard deviations from the mean for specifications.
Before production starts
A tool that shows performance along key dimensions all at once.

46. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
The target number of standard deviations from the mean for specifications.
Speed - courtesy - competence - and ease of repair.
The secondary characteristics of a product; "bells and whistles."

47. What is process capability?
The ability of a process to consistently meet customer specifications.
Technical quality is the "what" of the service; functional quality is the "how."
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
To manage the Six Sigma project.

48. List two components of internal failure.
Financial - customer - internal process - innovation and learning.
Actual drawings - layouts - maps - etc which show where a defect occurs
Scrap - rework - retest - downtime - yield losses - disposition costs.
Define - measure - analyze - improve - control.

49. Manual Test for Nomality
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
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
A tool that shows the physical flows through a space.
To mentor/coach (and sometimes train) black belts.

50. Who is a process owner?
5%
Linearity - normality - homoscedasticity - independence.
Upper control limit.
The manager in charge of a process being improved in a Six Sigma project.