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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 the difference between the way sampling is done for SPC and for acceptance sampling?
Sampling for SPC is done real time.
Can't tell without a Range chart.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Lower skill requirements - faster - less chance for error.

2. Define durability.
The ratio of outputs to inputs; 1-scrap.
Stratify a particular defect type according to logical criteria
X-bar-bar
Mean time to replacement.

3. What is FMEA?
Failure Modes and Effects Analysis
Someone who is consistently against virtually everything.
Kaoru Ishikawa.
Fishbone - cause-and-effect diagram.

4. If a three-stage process has 90% yields at each stage - what is the overall yield?
Blame.
0.9^3 or 72.9%
95%
If the Response vs. Levels graph if the response lines are not parallel (crossing)

5. What are the four categories of costs in Juran's framework?
Prevention - appraisal - internal failure - external failure.
Observed variation in response is caused by the input
99.73%
What the value of the dependent variable is when the independent variable is zero.

6. DFMEA
Technical quality is the "what" of the service; functional quality is the "how."
Initiated before or at design concept finalization
p-bar - the long-run percent defective.
Different types of defects are listed (used for Pareto chart)

7. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
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
Shifts - Trends - Repeating patterns - Correlation with known events
99.73%
5%

8. Pareto Analysis
To monitor a process when measurement by attribute is used.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
95%
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).

9. Statistical Hypothesis
To obtain a certain desirable outcome from the process
Studying firms with the best performance in a particular area.
Method developed by Ishikawa to graphically display the causes of any given problem
An assertion or conjecture concerning one or more populations

10. What is the 5S model?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
A time series plot.
10 if Almost impossible to detect
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

11. Disadvantages of DOE

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12. What is DMADV?
A tool that shows the physical flows through a space.
Define - measure - analyze - design - verify.
The gap between what management thinks customers want and what customers really want.
Walter A. Shewhart

13. Name the structure associated with Quality Function Deployment.
The number of standard deviations some value is from the mean.
The House of Quality.
No -- only if the process is also capable.
To obtain a certain desirable outcome from the process

14. Affinity Diagrams
Workers - machines - materials.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
What the value of the dependent variable is when the independent variable is zero.
Financial - customer - internal process - innovation and learning.

15. In the Service Quality Gap Model - what is Gap 1?
5%
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Lower skill requirements - faster - less chance for error.
The gap between what management thinks customers want and what customers really want.

16. What does a project prioritization matrix do?
No -- only if the process is also capable.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Assigns scores to weighted criteria for each project under consideration.
To do a capability study for a non-centered process.

17. Residual(eij)
Attribute
Define - measure - analyze - improve - control.
= yij - y(bar)i --> value minus sum of that treatment (of row)
5%

18. When yields decrease - what are the two effects on contribution?
Lean (or JIT).
Defects Per Million Opportunities
Fewer good units to sell - increased variable cost/unit.
Mean time to replacement.

19. Process check sheets
Central Limit Theorem
99.73%
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Used to create frequency distribution tally sheets

20. What is Little's Law?
Not necessarily.
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.
False - because each machine will have different natural tolerances.
Inventory = throughput x flow time.

21. In the Service Quality Gap Model - what is Gap 4?
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
Consumer risk.
The gap between what is promised and what is delivered.
10 for Hazardous without warning 1 for none

22. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
Rapid improvement process.
The House of Quality.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

23. What is CTQ?
Mean time to replacement.
Critical to quality.
Initiated before or at design concept finalization
To be a member of a Six Sigma project team.

24. What are the 5 Ss?
Sort - Set in Order - Shine - Standardize - Sustain
X-bar-bar
Blame.
No -- if it is not the same - it can only be worse!

25. FMEA
If the Response vs. Levels graph if the response lines are not parallel (crossing)
It looks to minimize the probability of a failure - or to minimize its effects
Workers - machines - materials.
A time series plot.

26. Complete this quality phrase: 'Fix the process - not the _____.'
Can't tell without a Range chart.
A tool that shows the physical flows through a space.
Blame.
QFD

27. What is a dashboard?
The cycle time required to meet demand.
A tool that shows performance along key dimensions all at once.
A tool that shows where there is waste in a process.
100%

28. How does Juran define quality?
= yij - y(bar)i --> value minus sum of that treatment (of row)
Taguchi
Mistake-proofing.
Fitness for use.

29. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
A time series plot.
To mentor/coach (and sometimes train) black belts.
Speed - courtesy - competence - and ease of repair.

30. What does the abbreviation UCL stand for?
Upper control limit.
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.
F_alpha - df(tr) - df (error)
The secondary characteristics of a product; "bells and whistles."

31. What is Value Stream Mapping?
A tool that shows where there is waste in a process.
Concluding there has been an effect/change when there has not.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Sort - Set in Order - Shine - Standardize - Sustain

32. What do you do when a process is out of control?
Look for the assignable cause of non-random variation.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Different types of defects are listed (used for Pareto chart)
Can't tell without a Range chart.

33. Regression
Represents the behavior of a process
The manager in charge of a process being improved in a Six Sigma project.
Shifts - Trends - Repeating patterns - Correlation with known events
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

34. Defect check sheets
=sqrt((p*(1-p)/n)
Method developed by Ishikawa to graphically display the causes of any given problem
Different types of defects are listed (used for Pareto chart)
A scatterplot.

35. Non-random patterns (Run Charts)
It looks to minimize the probability of a failure - or to minimize its effects
Define - measure - analyze - improve - control.
Large enough to find two of the attribute - on average.
Shifts - Trends - Repeating patterns - Correlation with known events

36. Define perceived quality (Garvin's framework).
The gap between what is promised and what is delivered.
A brainstorming tool that shows the connections between ideas.
Lower control limit.
Brand image.

37. Taguchi's experimental designs are of this type.
Variable.
Controlling quality at the source.
Fractional factorial designs (orthogonal arrays)
10 for Hazardous without warning 1 for none

38. What is a Gantt chart?
Shows the temporal flow of activities in a project network.
The gap between what management thinks customers want and the process specifications.
A tool that shows the physical flows through a space.
A tool that shows performance along key dimensions all at once.

39. Process occurance ranking
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Define - measure - analyze - design - verify.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

40. List Garvin's eight dimensions of product quality.
Kaoru Ishikawa.
Can't tell without a Range chart.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
95%

41. What is the difference between Lean and Six Sigma?
It looks to minimize the probability of a failure - or to minimize its effects
Represents the behavior of a process
Lean is waste reduction - Six Sigma is variation reduction.
Mean time to replacement.

42. Define features.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
A tool that shows the physical flows through a space.
The secondary characteristics of a product; "bells and whistles."
Fishbone - cause-and-effect diagram.

43. Definition of Interaction
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
A brainstorming tool that shows the connections between ideas.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The target number of standard deviations from the mean for specifications.

44. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
68%
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Linearity - normality - homoscedasticity - independence.
The ability of a process to consistently meet customer specifications.

45. What is a spaghetti diagram?
A brainstorming tool that shows the connections between ideas.
= 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
A tool that shows the physical flows through a space.
The gap between what management thinks customers want and the process specifications.

46. If you have calculated a Cpk - should you also calculate a Cp?
Represents the behavior of a process
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
A descending order-sorted bar chart with a cumulative percentage line.
A tool that shows the physical flows through a space.

47. What is a run chart?
X-bar-bar
=sqrt(Σ(x-x-bar)^2)/(n-1))
A tool that shows the physical flows through a space.
A time series plot.

48. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
QFD
95%
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Scrap - rework - retest - downtime - yield losses - disposition costs.

49. If a Cp shows that a process is not capable - should you calculate Cpk?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Sort - Set in Order - Shine - Standardize - Sustain
No -- if it is not the same - it can only be worse!
Is the way in which the failure is manifested.

50. Affinity Diagrams
= 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
Fitness for use.
Organize ideas into meaningful categories by recognizing their underlying similarity
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper