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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. If you can only collect categorical data - what type of SPC charting can you do?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Attribute.
Fitness for use.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

2. List two components of prevention cost.
Someone who is consistently against virtually everything.
Because the mean and standard deviation are independent of each other.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
The cycle time required to meet demand.

3. What are the 5 Ss?
Sort - Set in Order - Shine - Standardize - Sustain
Brand image.
Waste.
To monitor a process when measurement by attribute is used.

4. Creating a Run Chart
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Mean time to failure.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

5. What is DPMO?
99.73%
Stratify a particular defect type according to logical criteria
Defects Per Million Opportunities
Define - measure - analyze - improve - control.

6. Define aesthetic quality.
They move closer to the center line.
Deming.
Pleasing to the senses.
False - because each machine will have different natural tolerances.

7. Detection Criteria Ranking
10 if Almost impossible to detect
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).
The House of Quality.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

8. What is Little's Law?
Variable.
Inventory = throughput x flow time.
The secondary characteristics of a product; "bells and whistles."
The manager in charge of a process being improved in a Six Sigma project.

9. How does Juran define quality?
Fitness for use.
Studying firms with the best performance in a particular area.
Large enough to find two of the attribute - on average.
Linearity - normality - homoscedasticity - independence.

10. DFMEA
Initiated before or at design concept finalization
Shifts - Trends - Repeating patterns - Correlation with known events
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).
Lean (or JIT).

11. Your production process meets customer specifications. Is your process in control?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Not necessarily.
False - because each machine will have different natural tolerances.
The gap between what is promised and what is delivered.

12. A process is operating "in control." Does this mean the customer's requirements are met?
Is what induces the failure
They move closer to the center line.
No -- only if the process is also capable.
Sampling for SPC is done real time.

13. What are the Five Dimensions of Service Quality?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
X-bar-bar
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

14. What is FMEA?
Causes that lead to a particular effect.
Failure Modes and Effects Analysis
Prevention and appraisal costs are balanced against internal and external failure.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

15. What is poka yoke?
Fewer good units to sell - increased variable cost/unit.
To monitor a process when measurement by attribute is used.
The Japanese national quality award.
Mistake-proofing.

16. Simple Regression Analysis (one factor regression model)
Represents the behavior of a process
= 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
Blame.
Different types of defects are listed (used for Pareto chart)

17. Define conformance quality.
The degree to which a product meets pre-established standards.
=sqrt((p*(1-p)/n)
A diagram that shows the relationships between activities in a project network.
100%

18. What is muda
Waste.
An assertion or conjecture concerning one or more populations
Brand image.
The US national quality award.

19. Which quality guru developed the concept of loss to society?
Shows the temporal flow of activities in a project network.
Taguchi
Kaoru Ishikawa.
What the value of the dependent variable is when the independent variable is zero.

20. 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?
Mistake-proofing.
False - because each machine will have different natural tolerances.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Mean time to failure.

21. What is a run chart?
To obtain a certain desirable outcome from the process
Fewer good units to sell - increased variable cost/unit.
= 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 time series plot.

22. In the Service Quality Gap Model - what is Gap 1?
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
Before production starts
The gap between what management thinks customers want and what customers really want.
Deming.

23. Based on what principal can we use the normal distribution assumptions for SPC?
10 if Almost impossible to detect
Central Limit Theorem
Fractional factorial designs (orthogonal arrays)
The ability of a process to consistently meet customer specifications.

24. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
It looks to minimize the probability of a failure - or to minimize its effects
Different types of defects are listed (used for Pareto chart)
5%
The manager in charge of a process being improved in a Six Sigma project.

25. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
The gap between what management thinks customers want and what customers really want.
Mistake-proofing.
0.9^3 or 72.9%

26. When yields decrease - what are the two effects on contribution?
Brand image.
Fewer good units to sell - increased variable cost/unit.
Before production starts
68%

27. What size should samples be for attribute SPC?
Variable.
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.
Large enough to find two of the attribute - on average.
p-bar - the long-run percent defective.

28. Uses of regression - Control
To obtain a certain desirable outcome from the process
The ratio of outputs to inputs; 1-scrap.
Hold all input variables constant except one. Observe the response as you vary the single input.
Used to create frequency distribution tally sheets

29. PFMEA
Rapid improvement process.
Before production starts
Hold all input variables constant except one. Observe the response as you vary the single input.
= yij - y(bar)i --> value minus sum of that treatment (of row)

30. In a regression - what does the p value of F tell you?
Attribute
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).
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Represents the behavior of a process

31. TWO-DIMENTIONAL SCATTER PLOT
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Lower skill requirements - faster - less chance for error.
Prevention - appraisal - internal failure - external failure.

32. List two components of external failure.
The cycle time required to meet demand.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Is the consequence of the failure.
Someone who is consistently against virtually everything.

33. What is DMADV?
Waste.
Define - measure - analyze - design - verify.
Lower control limit.
Concluding there has been an effect/change when there has not.

34. What are the four categories of costs in Juran's framework?
The ratio of outputs to inputs; 1-scrap.
To mentor/coach (and sometimes train) black belts.
Prevention - appraisal - internal failure - external failure.
To obtain a certain desirable outcome from the process

35. List two components of internal failure.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Scrap - rework - retest - downtime - yield losses - disposition costs.
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).

36. What does the abbreviation LCL stand for?
Lower control limit.
The House of Quality.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
99.73%

37. Test for Independence
An assertion or conjecture concerning one or more populations
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Hold all input variables constant except one. Observe the response as you vary the single input.
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

38. What type of risk is associated with Type II Error?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Sampling for SPC is done real time.
No -- the variation also has to be random and "expected."
Consumer risk.

39. Define serviceability.
Speed - courtesy - competence - and ease of repair.
Walter A. Shewhart
The gap between what management thinks customers want and what customers really want.
The US national quality award.

40. What is the role of a green belt?
A scatterplot.
Walter A. Shewhart
To be a member of a Six Sigma project team.
Consumer risk.

41. What percentage of a normal distribution lies above the mean?
50%
Brand image.
The gap between what customers expect and the service they receive.
Speed - courtesy - competence - and ease of repair.

42. What type of risk is associated with Type 1 Error?
Brand image.
Producer risk.
Shifts - Trends - Repeating patterns - Correlation with known events
The gap between specifications and how service is performed.

43. Define benchmarking.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The House of Quality.
Financial - customer - internal process - innovation and learning.
Studying firms with the best performance in a particular area.

44. What is the Baldrige Award?
The US national quality award.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
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).
False - because each machine will have different natural tolerances.

45. What is the Deming Prize?
The Japanese national quality award.
Fractional factorial designs (orthogonal arrays)
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Fitness for use.

46. What is the 5S model?
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).
Variable.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Initiated before or at design concept finalization

47. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
The manager in charge of a process being improved in a Six Sigma project.
Prevention and appraisal costs are balanced against internal and external failure.

48. Affinity Diagrams
5%
An assertion or conjecture concerning one or more populations
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Organize ideas into meaningful categories by recognizing their underlying similarity

49. What is a CAVE man?
Mean time to replacement.
Someone who is consistently against virtually everything.
Defects Per Million Opportunities
Different types of defects are listed (used for Pareto chart)

50. What quality tool formally incorporates the voice of the customer?
Lower control limit.
Walter A. Shewhart
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
QFD