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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. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Shifts - Trends - Repeating patterns - Correlation with known events
The primary operating characteristics of a product.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Variable.

2. What is the role of a master black belt?
Is the consequence of the failure.
Causes that lead to a particular effect.
To mentor/coach (and sometimes train) black belts.
To manage the Six Sigma project.

3. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Because the mean and standard deviation are independent of each other.
QFD
Attribute
Not necessarily.

4. Define durability.
Mean time to replacement.
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.
Speed - courtesy - competence - and ease of repair.

5. What is the formula for the standard deviation of a proportion?
Attribute
=sqrt((p*(1-p)/n)
Lean (or JIT).
F_alpha - df(tr) - df (error)

6. What is a network diagram?
Before production starts
A diagram that shows the relationships between activities in a project network.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Mistake-proofing.

7. Does it ever make sense to accept a job when a process is incapable?
To obtain a certain desirable outcome from the process
It's good -- but it's still out of control!
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

8. Simple Regression Analysis (one factor regression model)
Hold all input variables constant except one. Observe the response as you vary the single 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
The House of Quality.
Fishbone - cause-and-effect diagram.

9. Which quality guru developed the concept of loss to society?
It's good -- but it's still out of control!
Taguchi
The gap between what is promised and what is delivered.
Is the way in which the failure is manifested.

10. What happens to control limits on an SPC chart when sample size is increased?
They move closer to the center line.
Critical to quality.
False - because each machine will have different natural tolerances.
Mean time to failure.

11. Define conformance quality.
F_alpha - df(tr) - df (error)
The gap between specifications and how service is performed.
The degree to which a product meets pre-established standards.
Producer risk.

12. What are the three main categories of assignable cause?
Workers - machines - materials.
Fitness for use.
Consumer risk.
Initiated before or at design concept finalization

13. What is DPMO?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
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
Defects Per Million Opportunities
Initiated before or at design concept finalization

14. Statistical Hypothesis
A random variable that summarizes the information from the sample(s).
An assertion or conjecture concerning one or more populations
68%
5%

15. What size should samples be for attribute SPC?
Kaoru Ishikawa.
Variable.
Define - measure - analyze - design - verify.
Large enough to find two of the attribute - on average.

16. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
100%
Shifts - Trends - Repeating patterns - Correlation with known events
Attribute.
Lean (or JIT).

17. List two components of external failure.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Mistake-proofing.
A diagram that shows the relationships between activities in a project network.
Critical to quality.

18. What are the four categories of costs in Juran's framework?
Supplier - input - process - output - customer.
Taguchi
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
Prevention - appraisal - internal failure - external failure.

19. List two components of internal failure.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
To monitor a process when measurement by attribute is used.
0.9^3 or 72.9%
Scrap - rework - retest - downtime - yield losses - disposition costs.

20. What is a Pareto chart?
Technical quality is the "what" of the service; functional quality is the "how."
99.73%
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.

21. What is FMEA?
Mistake-proofing.
Failure Modes and Effects Analysis
Stratify a particular defect type according to logical criteria
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

22. FMEA
Lean (or JIT).
Define - measure - analyze - improve - control.
It looks to minimize the probability of a failure - or to minimize its effects
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

23. To what does the Six in Six Sigma relate?
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
Financial - customer - internal process - innovation and learning.
5%
The target number of standard deviations from the mean for specifications.

24. PFMEA
Before production starts
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Prevention - appraisal - internal failure - external failure.
Shows the temporal flow of activities in a project network.

25. What is the center line of an X-bar chart?
X-bar-bar
To mentor/coach (and sometimes train) black belts.
A descending order-sorted bar chart with a cumulative percentage line.
The ratio of outputs to inputs; 1-scrap.

26. How are LQL and AQL determined in an acceptance sampling plan?
Observed variation in response is caused by the input
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
Through producer/consumer negotiation.
The gap between what management thinks customers want and the process specifications.

27. What is an affinity diagram?
The gap between specifications and how service is performed.
No -- only if the process is also capable.
The cycle time required to meet demand.
A brainstorming tool that shows the connections between ideas.

28. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Outside.
Conformance to specifications.
Fitness for use.
The number of standard deviations some value is from the mean.

29. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Rapid improvement process.
Controlling quality at the source.
68%
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).

30. What is Little's Law?
The secondary characteristics of a product; "bells and whistles."
The target number of standard deviations from the mean for specifications.
Inventory = throughput x flow time.
Concluding there has been an effect/change when there has not.

31. Define benchmarking.
Financial - customer - internal process - innovation and learning.
Studying firms with the best performance in a particular area.
Shows the temporal flow of 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

32. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
To mentor/coach (and sometimes train) black belts.
Shifts - Trends - Repeating patterns - Correlation with known events
Fractional factorial designs (orthogonal arrays)

33. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
Outside.
Is what induces the failure
Deming.

34. For what is a p-chart used?
The degree to which a product meets pre-established standards.
A time series plot.
Large enough to find two of the attribute - on average.
To monitor a process when measurement by attribute is used.

35. Complete this quality phrase: 'Fix the process - not the _____.'
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
False - because each machine will have different natural tolerances.
They move closer to the center line.
Blame.

36. Regression
It's good -- but it's still out of control!
Prevention - appraisal - internal failure - external failure.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Represents the behavior of a process

37. Define aesthetic quality.
Mean time to replacement.
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 primary operating characteristics of a product.
Pleasing to the senses.

38. Process occurance ranking
The House of Quality.
Used to create frequency distribution tally sheets
95%
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

39. What is muda
Waste.
= 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
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
100%

40. Which type of SPC measurement is more precise - variable or attribute?
To monitor a process when measurement by variables is used.
Variable.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Blame.

41. In a regression - what does the p value of F tell you?
Define - measure - analyze - improve - control.
Organize ideas into meaningful categories by recognizing their underlying similarity
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).
Rapid improvement process.

42. Name the structure associated with Quality Function Deployment.
The secondary characteristics of a product; "bells and whistles."
0.9^3 or 72.9%
The House of Quality.
The Japanese national quality award.

43. Explain the difference between technical and functional service 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
Lean is waste reduction - Six Sigma is variation reduction.
Initiated before or at design concept finalization
Technical quality is the "what" of the service; functional quality is the "how."

44. One factor at a time (OFAT)
68%
Rapid improvement process.
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.

45. Daniel Test
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
Fishbone - cause-and-effect diagram.
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:
What the value of the dependent variable is when the independent variable is zero.

46. What is the role of a green belt?
Organize ideas into meaningful categories by recognizing their underlying similarity
Upper control limit.
To be a member of a Six Sigma project team.
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).

47. DFMEA
Critical to quality.
Initiated before or at design concept finalization
The cycle time required to meet demand.
Observed variation in response is caused by the input

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

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49. What is the difference between Lean and Six Sigma?
Lean is waste reduction - Six Sigma is variation reduction.
Defects Per Million Opportunities
Deming.
To mentor/coach (and sometimes train) black belts.

50. Your production process meets customer specifications. Is your process in control?
Represents the behavior of a process
Critical to quality.
Is the consequence of the failure.
Not necessarily.