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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. Define product reliability.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
False - because each machine will have different natural tolerances.
Mean time to failure.
The ability of a process to consistently meet customer specifications.

2. What is the 5S model?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Defects Per Million Opportunities
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Represents the behavior of a process

3. Residual
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Assigns scores to weighted criteria for each project under consideration.
No -- if it is not the same - it can only be worse!
A random variable that summarizes the information from the sample(s).

4. What percentage of a normal distribution lies above the mean?
Stratify a particular defect type according to logical criteria
A brainstorming tool that shows the connections between ideas.
50%
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

5. Does it ever make sense to accept a job when a process is incapable?
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
An assertion or conjecture concerning one or more populations
Concluding there has not been an effect/change when there has.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

6. Uses of regression
Studying firms with the best performance in a particular area.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Inventory = throughput x flow time.

7. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
= 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
Producer risk.
To mentor/coach (and sometimes train) black belts.
Variable.

8. List two components of internal failure.
Prevention and appraisal costs are balanced against internal and external failure.
Conformance to specifications.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Attribute.

9. Who developed the fishbone diagram?
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
The cycle time required to meet demand.
Can't tell without a Range chart.
Kaoru Ishikawa.

10. What is process capability?
Workers - machines - materials.
The ability of a process to consistently meet customer specifications.
=sqrt((p*(1-p)/n)
The gap between what is promised and what is delivered.

11. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Lean (or JIT).
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

12. What is a Gantt chart?
Prevention and appraisal costs are balanced against internal and external failure.
Shows the temporal flow of activities in a project network.
99.73%
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

13. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
To obtain a certain desirable outcome from the process
Causes that lead to a particular effect.
Outside.
Mean time to replacement.

14. Define serviceability.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Speed - courtesy - competence - and ease of repair.
=sqrt(Σ(x-x-bar)^2)/(n-1))
The ratio of outputs to inputs; 1-scrap.

15. What is FMEA?
Failure Modes and Effects Analysis
A tool that shows performance along key dimensions all at once.
Fewer good units to sell - increased variable cost/unit.
The target number of standard deviations from the mean for specifications.

16. Based on what principal can we use the normal distribution assumptions for SPC?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Central Limit Theorem
10 for Hazardous without warning 1 for none
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

17. Residual(eij)
= yij - y(bar)i --> value minus sum of that treatment (of row)
Fewer good units to sell - increased variable cost/unit.
Different types of defects are listed (used for Pareto chart)
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

18. Define perceived quality (Garvin's framework).
Fewer good units to sell - increased variable cost/unit.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Brand image.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

19. Statistical Hypothesis
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
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
An assertion or conjecture concerning one or more populations
The ability of a process to consistently meet customer specifications.

20. In the Service Quality Gap Model - what is Gap 1?
10 for Hazardous without warning 1 for none
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Fishbone - cause-and-effect diagram.
The gap between what management thinks customers want and what customers really want.

21. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The primary operating characteristics of a product.
To mentor/coach (and sometimes train) black belts.
Conformance to specifications.

22. What is the center line of an X-bar chart?
Sort - Set in Order - Shine - Standardize - Sustain
X-bar-bar
No -- if it is not the same - it can only be worse!
Can't tell without a Range chart.

23. Histogram by Hand
Reliability - Assurance - Responsiveness - Tangibles - Empathy
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
A diagram that shows the relationships between activities in a project network.
To obtain a certain desirable outcome from the process

24. Regression
5%
Represents the behavior of a process
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).
Is what induces the failure

25. Define performance quality.
Someone who is consistently against virtually everything.
The primary operating characteristics of a product.
Blame.
What the value of the dependent variable is when the independent variable is zero.

26. List two appraisal costs.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
A tool that shows the physical flows through a space.
It looks to minimize the probability of a failure - or to minimize its effects
Upper control limit.

27. Defect check sheets
A tool that shows the physical flows through a space.
Deming.
Different types of defects are listed (used for Pareto chart)
To monitor a process when measurement by variables is used.

28. Design of Experiments (DOE) approach
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
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
To manage the Six Sigma project.

29. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
No -- the variation also has to be random and "expected."
Not necessarily.
Because the mean and standard deviation are independent of each other.
Financial - customer - internal process - innovation and learning.

30. Non-random patterns (Run Charts)
Shifts - Trends - Repeating patterns - Correlation with known events
Attribute
The number of standard deviations some value is from the mean.
100%

31. Stratified defect check sheets
A descending order-sorted bar chart with a cumulative percentage line.
Stratify a particular defect type according to logical criteria
Observed variation in response is caused by the input
To manage the Six Sigma project.

32. What size should samples be for attribute SPC?
X-bar-bar
Large enough to find two of the attribute - on average.
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:
Shifts - Trends - Repeating patterns - Correlation with known events

33. ANOVA

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34. What are the 5 Ss?
Sort - Set in Order - Shine - Standardize - Sustain
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
10 for Hazardous without warning 1 for none
Not necessarily.

35. What quality tool formally incorporates the voice of the customer?
Different types of defects are listed (used for Pareto chart)
QFD
10 for Hazardous without warning 1 for none
Pleasing to the senses.

36. What is an affinity diagram?
To manage the Six Sigma project.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
A brainstorming tool that shows the connections between ideas.
Central Limit Theorem

37. Regression Analysis
Method developed by Ishikawa to graphically display the causes of any given problem
To manage the Six Sigma project.
Financial - customer - internal process - innovation and learning.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

38. Risk Priority Number RPN
Attribute.
Workers - machines - materials.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Linearity - normality - homoscedasticity - independence.

39. Define yield.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
3.4 (assuming 1.5 sigma shift in the mean)
The ratio of outputs to inputs; 1-scrap.
Concluding there has been an effect/change when there has not.

40. Failure cause
Inventory = throughput x flow time.
50%
Shifts - Trends - Repeating patterns - Correlation with known events
Is what induces the failure

41. Your production process meets customer specifications. Is your process in control?
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
Not necessarily.
Workers - machines - materials.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

42. Failure effect
X-bar-bar
= 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
Lower control limit.
Is the consequence of the failure.

43. DFMEA
Initiated before or at design concept finalization
A scatterplot.
Attribute
Rapid improvement process.

44. How does Juran define quality?
Lean (or JIT).
Walter A. Shewhart
A scatterplot.
Fitness for use.

45. What is muda
99.73%
Waste.
A tool that shows the physical flows through a space.
Mean time to failure.

46. If you have calculated a Cpk - should you also calculate a Cp?
Supplier - input - process - output - customer.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Is the consequence of the failure.
Central Limit Theorem

47. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Scrap - rework - retest - downtime - yield losses - disposition costs.
95%
If the Response vs. Levels graph if the response lines are not parallel (crossing)

48. F value
Mistake-proofing.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Outside.
F_alpha - df(tr) - df (error)

49. What does the abbreviation UCL stand for?
To manage the Six Sigma project.
A tool that shows performance along key dimensions all at once.
Upper control limit.
Method developed by Ishikawa to graphically display the causes of any given problem

50. What happens to control limits on an SPC chart when sample size is increased?
Not necessarily.
They move closer to the center line.
The gap between what is promised and what is delivered.
Kaoru Ishikawa.