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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 Baldrige Award?
Before production starts
The US national quality award.
Mean time to failure.
10 if Almost impossible to detect

2. What is the formula for the standard deviation of a proportion?
Walter A. Shewhart
=sqrt((p*(1-p)/n)
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

3. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Sampling for SPC is done real time.
The US national quality award.
To do a capability study for a non-centered process.
Not necessarily.

4. Process occurance ranking
They move closer to the center line.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
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).
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

5. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Large enough to find two of the attribute - on average.
68%
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).
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

6. Affinity Diagrams
The gap between what customers expect and the service they receive.
Assigns scores to weighted criteria for each project under consideration.
=sqrt((p*(1-p)/n)
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

7. What is Value Stream Mapping?
A tool that shows where there is waste in a process.
Mean time to replacement.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

8. Presence of interaction effect
A time series plot.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
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
Not necessarily.

9. What do you do when a process is out of control?
The House of Quality.
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:
Look for the assignable cause of non-random variation.
Variable.

10. 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?
False - because each machine will have different natural tolerances.
Is the way in which the failure is manifested.
They move closer to the center line.
Shows the temporal flow of activities in a project network.

11. List two components of external failure.
QFD
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
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 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

12. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Actual drawings - layouts - maps - etc which show where a defect occurs
A tool that shows the physical flows through a space.
No -- the variation also has to be random and "expected."
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

13. Advantages of DOE
Central Limit Theorem
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
Variable.
A time series plot.

14. In the Service Quality Gap Model - what is Gap 2?
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
Look for the assignable cause of non-random variation.
The gap between what management thinks customers want and the process specifications.
Not necessarily.

15. What is process capability?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Hold all input variables constant except one. Observe the response as you vary the single input.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The ability of a process to consistently meet customer specifications.

16. What is the center line of a p-chart?
Fishbone - cause-and-effect diagram.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
p-bar - the long-run percent defective.
The ratio of outputs to inputs; 1-scrap.

17. Definition of Interaction
The number of standard deviations some value is from the mean.
= yij - y(bar)i --> value minus sum of that treatment (of row)
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Not necessarily.

18. What type of risk is associated with Type 1 Error?
Consumer risk.
Producer risk.
A tool that shows where there is waste in a process.
=sqrt((p*(1-p)/n)

19. What does DMAIC stand for?
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).
Define - measure - analyze - improve - control.
Assigns scores to weighted criteria for each project under consideration.
Can't tell without a Range chart.

20. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
Central Limit Theorem
Concluding there has not been an effect/change when there has.
F_alpha - df(tr) - df (error)

21. What is CTQ?
Central Limit Theorem
Critical to quality.
Concluding there has not been an effect/change when there has.
Assigns scores to weighted criteria for each project under consideration.

22. If you can only collect categorical data - what type of SPC charting can you do?
Critical to quality.
Is what induces the failure
Attribute.
Assigns scores to weighted criteria for each project under consideration.

23. In a Z table - what is Z?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
The number of standard deviations some value is from the mean.
Initiated before or at design concept finalization
Scrap - rework - retest - downtime - yield losses - disposition costs.

24. How are LQL and AQL determined in an acceptance sampling plan?
Defects Per Million Opportunities
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.
Through producer/consumer negotiation.

25. What is Little's Law?
Is what induces the failure
50%
Fishbone - cause-and-effect diagram.
Inventory = throughput x flow time.

26. What is Type 1 Error?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Concluding there has been an effect/change when there has not.
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
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

27. Which quality guru developed the concept of loss to society?
The primary operating characteristics of a product.
Stratify a particular defect type according to logical criteria
Taguchi
Producer risk.

28. Define yield.
Mean time to replacement.
The ratio of outputs to inputs; 1-scrap.
Upper control limit.
Critical to quality.

29. What is muda
The manager in charge of a process being improved in a Six Sigma project.
Prevention - appraisal - internal failure - external failure.
Waste.
Method developed by Ishikawa to graphically display the causes of any given problem

30. Define perceived quality (Garvin's framework).
10 if Almost impossible to detect
5%
=sqrt(Σ(x-x-bar)^2)/(n-1))
Brand image.

31. What is a Pareto chart?
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 descending order-sorted bar chart with a cumulative percentage line.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Producer risk.

32. With Six Sigma capability - how many defects per million opportunities would you see?
A diagram that shows the relationships between activities in a project network.
3.4 (assuming 1.5 sigma shift in the mean)
Sampling for SPC is done real time.
Represents the behavior of a process

33. TWO-DIMENTIONAL SCATTER PLOT
Prevention and appraisal costs are balanced against internal and external failure.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
A tool that shows the physical flows through a space.
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

34. What graphical tool is used to show the relationship between two numerical variables?
The gap between what management thinks customers want and the process specifications.
95%
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 scatterplot.

35. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
Fitness for use.
To manage the Six Sigma project.
Pleasing to the senses.

36. What quality tool formally incorporates the voice of the customer?
Look for the assignable cause of non-random variation.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Linearity - normality - homoscedasticity - independence.
QFD

37. Failure Mode
Actual drawings - layouts - maps - etc which show where a defect occurs
Initiated before or at design concept finalization
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
Is the way in which the failure is manifested.

38. Residual(eij)
= yij - y(bar)i --> value minus sum of that treatment (of row)
Rapid improvement process.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Can't tell without a Range chart.

39. How does Juran define quality?
Fitness for use.
A time series plot.
The gap between specifications and how service is performed.
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

40. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
95%
0.9^3 or 72.9%
Taguchi
Look for the assignable cause of non-random variation.

41. List two components of prevention cost.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
100%
To do a capability study for a non-centered process.
The gap between what is promised and what is delivered.

42. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Lower skill requirements - faster - less chance for error.
Initiated before or at design concept finalization
Actual drawings - layouts - maps - etc which show where a defect occurs
Mistake-proofing.

43. A process is operating "in control." Does this mean the customer's requirements are met?
No -- only if the process is also capable.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Mean time to failure.
It looks to minimize the probability of a failure - or to minimize its effects

44. Regression Analysis
=sqrt((p*(1-p)/n)
Failure Modes and Effects Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
To mentor/coach (and sometimes train) black belts.

45. Based on what principal can we use the normal distribution assumptions for SPC?
To monitor a process when measurement by variables is used.
Inventory = throughput x flow time.
Central Limit Theorem
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

46. What are the four perspectives of the Balanced Scorecard?
Look for the assignable cause of non-random variation.
Financial - customer - internal process - innovation and learning.
Someone who is consistently against virtually everything.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

47. Define aesthetic quality.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
QFD
A tool that shows where there is waste in a process.
Pleasing to the senses.

48. 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.
Observed variation in response is caused by the input
100%
A tool that shows where there is waste in a process.

49. What does the abbreviation UCL stand for?
=sqrt(Σ(x-x-bar)^2)/(n-1))
50%
Upper control limit.
Conformance to specifications.

50. Define product reliability.
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
Rapid improvement process.
Prevention and appraisal costs are balanced against internal and external failure.
Mean time to failure.