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Six Sigma

Subjects : certifications, six-sigma, business-skills

Instructions:

Answer 50 questions in 15 minutes.
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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 process capability?
The ability of a process to consistently meet customer specifications.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
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
Producer risk.

2. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Supplier - input - process - output - customer.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Lean (or JIT).
A random variable that summarizes the information from the sample(s).

3. Process check sheets
Used to create frequency distribution tally sheets
Inventory = throughput x flow time.
Is the way in which the failure is manifested.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

4. What are the four categories of costs in Juran's framework?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Prevention - appraisal - internal failure - external failure.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
The number of standard deviations some value is from the mean.

5. Based on what principal can we use the normal distribution assumptions for SPC?
Variable.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Central Limit Theorem
The US national quality award.

6. Define perceived quality (Garvin's framework).
Shifts - Trends - Repeating patterns - Correlation with known events
Brand image.
Sampling for SPC is done real time.
5%

7. What is Value Stream Mapping?
The House of Quality.
Causes that lead to a particular effect.
Through producer/consumer negotiation.
A tool that shows where there is waste in a process.

8. What is the role of a master black belt?
What the value of the dependent variable is when the independent variable is zero.
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).
To mentor/coach (and sometimes train) black belts.
Is the way in which the failure is manifested.

9. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Taguchi
Lower control limit.
Outside.
Actual drawings - layouts - maps - etc which show where a defect occurs

10. What is a Pareto chart?
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
A descending order-sorted bar chart with a cumulative percentage line.
Variable.
Workers - machines - materials.

11. Risk Priority Number RPN
A tool that shows where there is waste in a process.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Mean time to failure.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

12. Who first studied randomness in industrial processes
It looks to minimize the probability of a failure - or to minimize its effects
Walter A. Shewhart
100%
A scatterplot.

13. What is an affinity diagram?
A brainstorming tool that shows the connections between ideas.
Fitness for use.
Sort - Set in Order - Shine - Standardize - Sustain
No -- if it is not the same - it can only be worse!

14. What are the three main categories of assignable cause?
Workers - machines - materials.
The gap between what management thinks customers want and what customers really want.
Pleasing to the senses.
50%

15. DOE
The degree to which a product meets pre-established standards.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Producer risk.

16. Explain the difference between technical and functional service quality.
Technical quality is the "what" of the service; functional quality is the "how."
Blame.
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
Inventory = throughput x flow time.

17. Pareto Analysis
Producer risk.
The US national quality award.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
95%

18. Define features.
The secondary characteristics of a product; "bells and whistles."
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
Fishbone - cause-and-effect diagram.
Observed variation in response is caused by the input

19. What is a Gantt chart?
Shows the temporal flow of activities in a project network.
A tool that shows the physical flows through a space.
No -- only if the process is also capable.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

20. The Test Statistic (TS)
Because the mean and standard deviation are independent of each other.
A random variable that summarizes the information from the sample(s).
Mean time to failure.
Attribute

21. What is the difference between the way sampling is done for SPC and for acceptance sampling?
To manage the Six Sigma project.
To monitor a process when measurement by variables is used.
X-bar-bar
Sampling for SPC is done real time.

22. In a regression - what does R-square tell you?
An assertion or conjecture concerning one or more populations
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

23. How are LQL and AQL determined in an acceptance sampling plan?
Through producer/consumer negotiation.
Sort - Set in Order - Shine - Standardize - Sustain
It looks to minimize the probability of a failure - or to minimize its effects
Technical quality is the "what" of the service; functional quality is the "how."

24. Affinity Diagrams
99.73%
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

25. In the Service Quality Gap Model - what is Gap 1?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
The gap between what management thinks customers want and what customers really want.
A tool that shows performance along key dimensions all at once.
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.

26. What is the role of a black belt?
To monitor a process when measurement by variables is used.
F_alpha - df(tr) - df (error)
The degree to which a product meets pre-established standards.
To manage the Six Sigma project.

27. Test for constant variance
Conformance to specifications.
To do a capability study for a non-centered process.
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.
95%

28. What does a project prioritization matrix do?
Lean is waste reduction - Six Sigma is variation reduction.
The secondary characteristics of a product; "bells and whistles."
Hold all input variables constant except one. Observe the response as you vary the single input.
Assigns scores to weighted criteria for each project under consideration.

29. What is Type 1 Error?
To obtain a certain desirable outcome from the process
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Sampling for SPC is done real time.
Concluding there has been an effect/change when there has not.

30. What is FMEA?
Variable.
Is the way in which the failure is manifested.
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:
Failure Modes and Effects Analysis

31. List two components of prevention cost.
To monitor a process when measurement by variables is used.
5%
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

32. What is a CAVE man?
Someone who is consistently against virtually everything.
Lower control limit.
A diagram that shows the relationships between activities in a project network.
Speed - courtesy - competence - and ease of repair.

33. Define product reliability.
Mean time to failure.
Failure Modes and Effects Analysis
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The primary operating characteristics of a product.

34. In a Z table - what is Z?
The number of standard deviations some value is from the mean.
Fitness for use.
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
Is what induces the failure

35. What is CTQ?
Critical to quality.
To manage the Six Sigma project.
Is the consequence of the failure.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

36. When yields decrease - what are the two effects on contribution?
No -- if it is not the same - it can only be worse!
The gap between what management thinks customers want and the process specifications.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Fewer good units to sell - increased variable cost/unit.

37. In the Service Quality Gap Model - what is Gap 2?
No -- the variation also has to be random and "expected."
Critical to quality.
The gap between what management thinks customers want and the process specifications.
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

38. Definition of Interaction
Define - measure - analyze - design - verify.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The House of Quality.
68%

39. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Workers - machines - materials.
The gap between what management thinks customers want and what customers really want.
A diagram that shows the relationships between activities in a project network.
No -- the variation also has to be random and "expected."

40. Stratified defect check sheets
Scrap - rework - retest - downtime - yield losses - disposition costs.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Stratify a particular defect type according to logical criteria
Lower control limit.

41. Failure cause
Is what induces the failure
Studying firms with the best performance in a particular area.
Fitness for use.
10 if Almost impossible to detect

42. Define takt time.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Rapid improvement process.
The cycle time required to meet demand.
F_alpha - df(tr) - df (error)

43. For what is an x-bar chart used?
0.9^3 or 72.9%
The number of standard deviations some value is from the mean.
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 monitor a process when measurement by variables is used.

44. What is the formula for standard deviation?
p-bar - the long-run percent defective.
Hold all input variables constant except one. Observe the response as you vary the single input.
False - because each machine will have different natural tolerances.
=sqrt(Σ(x-x-bar)^2)/(n-1))

45. FMEA
The degree to which a product meets pre-established standards.
68%
It looks to minimize the probability of a failure - or to minimize its effects
Assigns scores to weighted criteria for each project under consideration.

46. Defect check sheets
The gap between specifications and how service is performed.
Different types of defects are listed (used for Pareto chart)
Defects Per Million Opportunities
To monitor a process when measurement by attribute is used.

47. In the Service Quality Gap Model - what is Gap 5?
The gap between what customers expect and the service they receive.
The gap between what management thinks customers want and what customers really want.
Conformance to specifications.
A tool that shows the physical flows through a space.

48. Regression
The gap between specifications and how service is performed.
Upper control limit.
Represents the behavior of a process
The manager in charge of a process being improved in a Six Sigma project.

49. What is the center line of an X-bar chart?
=sqrt(Σ(x-x-bar)^2)/(n-1))
X-bar-bar
The degree to which a product meets pre-established standards.
Is what induces the failure

50. Define aesthetic quality.
The gap between what customers expect and the service they receive.
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
Pleasing to the senses.
Workers - machines - materials.

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