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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 a Gantt chart?
=sqrt((p*(1-p)/n)
Conformance to specifications.
Shows the temporal flow of activities in a project network.
Is the consequence of the failure.

2. Define durability.
The gap between what management thinks customers want and the process specifications.
Mean time to replacement.
The House of Quality.
=sqrt(Σ(x-x-bar)^2)/(n-1))

3. In a Z table - what is Z?
The number of standard deviations some value is from the mean.
Lower skill requirements - faster - less chance for error.
Supplier - input - process - output - customer.
Financial - customer - internal process - innovation and learning.

4. What is a dashboard?
Upper control limit.
0.9^3 or 72.9%
Reliability - Assurance - Responsiveness - Tangibles - Empathy
A tool that shows performance along key dimensions all at once.

5. Define perceived quality (Garvin's framework).
Before production starts
Linearity - normality - homoscedasticity - independence.
Brand image.
The House of Quality.

6. Process check sheets
To monitor a process when measurement by variables is used.
A tool that shows the physical flows through a space.
Used to create frequency distribution tally sheets
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

7. Define takt time.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Different types of defects are listed (used for Pareto chart)
The manager in charge of a process being improved in a Six Sigma project.
The cycle time required to meet demand.

8. Define benchmarking.
Studying firms with the best performance in a particular area.
Actual drawings - layouts - maps - etc which show where a defect occurs
Fewer good units to sell - increased variable cost/unit.
10 for Hazardous without warning 1 for none

9. What is Jidoka?
Sampling for SPC is done real time.
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
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
Controlling quality at the source.

10. Who developed the fishbone diagram?
Kaoru Ishikawa.
Define - measure - analyze - improve - control.
Lean is waste reduction - Six Sigma is variation reduction.
Sort - Set in Order - Shine - Standardize - Sustain

11. What is Type II Error?
Taguchi
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Waste.
Concluding there has not been an effect/change when there has.

12. ANOVA

13. What are the Five Dimensions of Service Quality?
Mean time to failure.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Stratify a particular defect type according to logical criteria
Fitness for use.

14. Which quality guru developed the concept of loss to society?
Taguchi
A descending order-sorted bar chart with a cumulative percentage line.
= yij - y(bar)i --> value minus sum of that treatment (of row)
=sqrt((p*(1-p)/n)

15. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
Attribute.
Not necessarily.
Different types of defects are listed (used for Pareto chart)
100%

16. What happens to control limits on an SPC chart when sample size is increased?
They move closer to the center line.
Studying firms with the best performance in a particular area.
Look for the assignable cause of non-random variation.
A time series plot.

17. Detection Criteria Ranking
The gap between what management thinks customers want and what customers really want.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
10 if Almost impossible to detect

18. What quality tool formally incorporates the voice of the customer?
False - because each machine will have different natural tolerances.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
QFD
Central Limit Theorem

19. How does Juran define quality?
A brainstorming tool that shows the connections between ideas.
Rapid improvement process.
Central Limit Theorem
Fitness for use.

20. Define conformance quality.
99.73%
The degree to which a product meets pre-established standards.
Linearity - normality - homoscedasticity - independence.
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

21. Design of Experiments (DOE) approach
A descending order-sorted bar chart with a cumulative percentage line.
A brainstorming tool that shows the connections between ideas.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Different types of defects are listed (used for Pareto chart)

22. What is poka yoke?
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).
Studying firms with the best performance in a particular area.
Mistake-proofing.
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

23. FMEA
Kaoru Ishikawa.
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
Fitness for use.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

24. Define yield.
Failure Modes and Effects Analysis
Fishbone - cause-and-effect diagram.
The ratio of outputs to inputs; 1-scrap.
Taguchi

25. In the Service Quality Gap Model - what is Gap 4?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
To manage the Six Sigma project.
No -- only if the process is also capable.
The gap between what is promised and what is delivered.

26. Simple Regression Analysis (one factor regression model)
A diagram that shows the relationships between activities in a project network.
= 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
100%
Rapid improvement process.

27. Non-random patterns (Run Charts)
To mentor/coach (and sometimes train) black belts.
Shifts - Trends - Repeating patterns - Correlation with known events
The number of standard deviations some value is from the mean.
Linearity - normality - homoscedasticity - independence.

28. Complete this quality phrase: 'Fix the process - not the _____.'
Blame.
Prevention - appraisal - internal failure - external failure.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Different types of defects are listed (used for Pareto chart)

29. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
Causes that lead to a particular effect.
100%
A diagram that shows the relationships between activities in a project network.

30. What is written on the "spines" of a fishbone diagram?
Concluding there has been an effect/change when there has not.
The House of Quality.
The gap between what is promised and what is delivered.
Causes that lead to a particular effect.

31. 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!
= yij - y(bar)i --> value minus sum of that treatment (of row)
Pleasing to the senses.
Different types of defects are listed (used for Pareto chart)

32. Who is a process owner?
=sqrt(Σ(x-x-bar)^2)/(n-1))
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
The manager in charge of a process being improved in a Six Sigma project.
To monitor a process when measurement by attribute is used.

33. PFMEA
Before production starts
False - because each machine will have different natural tolerances.
The target number of standard deviations from the mean for specifications.
Supplier - input - process - output - customer.

34. A process is operating "in control." Does this mean the customer's requirements are met?
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:
No -- only if the process is also capable.
= 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
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

35. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Blame.
Prevention - appraisal - internal failure - external failure.
Lean (or JIT).
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

36. What is CTQ?
The US national quality award.
68%
Critical to quality.
Causes that lead to a particular effect.

37. Taguchi's experimental designs are of this type.
They move closer to the center line.
Fractional factorial designs (orthogonal arrays)
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
The degree to which a product meets pre-established standards.

38. FMEA
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
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."
Can't tell without a Range chart.

39. For what is a p-chart used?
Fewer good units to sell - increased variable cost/unit.
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:
To monitor a process when measurement by attribute is used.
Is the way in which the failure is manifested.

40. Affinity Diagrams
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Someone who is consistently against virtually everything.
Represents the behavior of a process
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:

41. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
0.9^3 or 72.9%
Kaoru Ishikawa.

42. For what is an x-bar chart used?
To monitor a process when measurement by variables is used.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
99.73%
Inventory = throughput x flow time.

43. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Stratify a particular defect type according to logical criteria
Sampling for SPC is done real time.
10 for Hazardous without warning 1 for none
The primary operating characteristics of a product.

44. To what does the Six in Six Sigma relate?
95%
= 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 random variable that summarizes the information from the sample(s).
The target number of standard deviations from the mean for specifications.

45. One factor at a time (OFAT)
3.4 (assuming 1.5 sigma shift in the mean)
Hold all input variables constant except one. Observe the response as you vary the single input.
No -- the variation also has to be random and "expected."
A descending order-sorted bar chart with a cumulative percentage line.

46. What is DPMO?
Defects Per Million Opportunities
To do a capability study for a non-centered process.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
=sqrt((p*(1-p)/n)

47. Name the structure associated with Quality Function Deployment.
Brand image.
The House of Quality.
Workers - machines - materials.
A tool that shows the physical flows through a space.

48. What graphical tool is used to show the relationship between two numerical variables?
Conformance to specifications.
A scatterplot.
Initiated before or at design concept finalization
To monitor a process when measurement by variables is used.

49. Defect check sheets
Different types of defects are listed (used for Pareto chart)
3.4 (assuming 1.5 sigma shift in the mean)
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
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:

50. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Mean time to replacement.
X-bar-bar
Variable.
Fitness for use.