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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. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
The secondary characteristics of a product; "bells and whistles."
No -- the variation also has to be random and "expected."
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

2. Taguchi's experimental designs are of this type.
Defects Per Million Opportunities
The gap between what is promised and what is delivered.
Fractional factorial designs (orthogonal arrays)
To monitor a process when measurement by variables is used.

3. Process occurance ranking
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.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The ability of a process to consistently meet customer specifications.

4. Defect location check sheets
10 if Almost impossible to detect
Actual drawings - layouts - maps - etc which show where a defect occurs
False - because each machine will have different natural tolerances.
Used to create frequency distribution tally sheets

5. What does Crosby say about benchmarking?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Controlling quality at the source.
The target number of standard deviations from the mean for specifications.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

6. Which quality guru developed the concept of loss to society?
Taguchi
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
Shifts - Trends - Repeating patterns - Correlation with known events
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

7. For what is an x-bar chart used?
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 monitor a process when measurement by variables is used.
= yij - y(bar)i --> value minus sum of that treatment (of row)
An assertion or conjecture concerning one or more populations

8. What are the four categories of costs in Juran's framework?
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."
Prevention - appraisal - internal failure - external failure.
10 if Almost impossible to detect

9. What is the formula for standard deviation?
50%
Controlling quality at the source.
=sqrt(Σ(x-x-bar)^2)/(n-1))
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).

10. What is written on the "spines" of a fishbone diagram?
Because the mean and standard deviation are independent of each other.
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
Causes that lead to a particular effect.
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).

11. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Consumer risk.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Attribute

12. What is Kaizen?
Lean (or JIT).
Rapid improvement process.
Prevention - appraisal - internal failure - external failure.
Define - measure - analyze - design - verify.

13. Who developed the fishbone diagram?
=sqrt((p*(1-p)/n)
Workers - machines - materials.
Kaoru Ishikawa.
= 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

14. What is DMADV?
Define - measure - analyze - design - verify.
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
Initiated before or at design concept finalization
Concluding there has not been an effect/change when there has.

15. There are two milling machines in the shop. Data has been collected on one to compute control limits for both. This is acceptable SPC practice - true or false and why?
3.4 (assuming 1.5 sigma shift in the mean)
False - because each machine will have different natural tolerances.
Observed variation in response is caused by the input
Assigns scores to weighted criteria for each project under consideration.

16. Manual Test for Nomality
Initiated before or at design concept finalization
A random variable that summarizes the information from the sample(s).
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Pleasing to the senses.

17. What does a project prioritization matrix do?
A random variable that summarizes the information from the sample(s).
The ability of a process to consistently meet customer specifications.
Assigns scores to weighted criteria for each project under consideration.
Variable.

18. What is Type II Error?
Concluding there has not been an effect/change when there has.
Fitness for use.
Upper control limit.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

19. Histogram by Hand
Walter A. Shewhart
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The ratio of outputs to inputs; 1-scrap.
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

20. Does it ever make sense to accept a job when a process is incapable?
To mentor/coach (and sometimes train) black belts.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Upper control limit.

21. What is the Baldrige Award?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Upper control limit.
100%
The US national quality award.

22. How does Juran define quality?
Sampling for SPC is done real time.
Pleasing to the senses.
Fitness for use.
99.73%

23. What does SIPOC stand for?
Organize ideas into meaningful categories by recognizing their underlying similarity
= yij - y(bar)i --> value minus sum of that treatment (of row)
=sqrt(Σ(x-x-bar)^2)/(n-1))
Supplier - input - process - output - customer.

24. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Conformance to specifications.
Through producer/consumer negotiation.
Fishbone - cause-and-effect diagram.
An assertion or conjecture concerning one or more populations

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

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26. If a Cp shows that a process is not capable - should you calculate Cpk?
No -- if it is not the same - it can only be worse!
Lean is waste reduction - Six Sigma is variation reduction.
Sampling for SPC is done real time.
Critical to quality.

27. In a regression - what does the coefficient of the intercept tell you
What the value of the dependent variable is when the independent variable is zero.
Is the way in which the failure is manifested.
Speed - courtesy - competence - and ease of repair.
Through producer/consumer negotiation.

28. Uses of regression
Represents the behavior of a process
Waste.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

29. Name the structure associated with Quality Function Deployment.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
They move closer to the center line.
The House of Quality.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

30. What does the abbreviation UCL stand for?
Fitness for use.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Upper control limit.
Attribute

31. Daniel Test
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:
Stratify a particular defect type according to logical criteria
Producer risk.
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

32. Pareto Analysis
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
A random variable that summarizes the information from the sample(s).
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

33. Advantages of DOE
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
p-bar - the long-run percent defective.

34. Uses of regression - Control
The ability of a process to consistently meet customer specifications.
The gap between what management thinks customers want and what customers really want.
To obtain a certain desirable outcome from the process
Kaoru Ishikawa.

35. Effect ranking (Severity of the Defect)
Look for the assignable cause of non-random variation.
10 for Hazardous without warning 1 for none
QFD
Attribute.

36. Regression
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Lean (or JIT).
Represents the behavior of a process
Mean time to failure.

37. How are LQL and AQL determined in an acceptance sampling plan?
Through producer/consumer negotiation.
95%
Critical to quality.
A random variable that summarizes the information from the sample(s).

38. Define takt time.
The cycle time required to meet demand.
Assigns scores to weighted criteria for each project under consideration.
Look for the assignable cause of non-random variation.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

39. Affinity Diagrams
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
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
They move closer to the center line.
Organize ideas into meaningful categories by recognizing their underlying similarity

40. List Garvin's eight dimensions of product quality.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Mean time to failure.
No -- only if the process is also capable.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

41. What is Type 1 Error?
The gap between what customers expect and the service they receive.
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).
Deming.
Concluding there has been an effect/change when there has not.

42. Define performance quality.
Central Limit Theorem
The primary operating characteristics of a product.
Studying firms with the best performance in a particular area.
95%

43. DFMEA
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
Initiated before or at design concept finalization
Controlling quality at the source.
Lower control limit.

44. Test for constant variance
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.
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
What the value of the dependent variable is when the independent variable is zero.
The cycle time required to meet demand.

45. What type of risk is associated with Type 1 Error?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Producer risk.
Define - measure - analyze - improve - control.
Waste.

46. List two components of prevention cost.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
10 for Hazardous without warning 1 for none
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

47. Residual
=sqrt(Σ(x-x-bar)^2)/(n-1))
Outside.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Fractional factorial designs (orthogonal arrays)

48. Define aesthetic quality.
= 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
Someone who is consistently against virtually everything.
A time series plot.
Pleasing to the senses.

49. With Six Sigma capability - how many defects per million opportunities would you see?
Technical quality is the "what" of the service; functional quality is the "how."
3.4 (assuming 1.5 sigma shift in the mean)
Lean is waste reduction - Six Sigma is variation reduction.
Prevention - appraisal - internal failure - external failure.

50. If you can only collect categorical data - what type of SPC charting can you do?
A brainstorming tool that shows the connections between ideas.
Not necessarily.
Attribute.
50%