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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. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Someone who is consistently against virtually everything.
Conformance to specifications.
The House of Quality.
95%

2. If you have calculated a Cpk - should you also calculate a Cp?
=sqrt((p*(1-p)/n)
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
To obtain a certain desirable outcome from the process
Method developed by Ishikawa to graphically display the causes of any given problem

3. Histogram by Hand
Prevention and appraisal costs are balanced against internal and external failure.
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
Lower control limit.
Defects Per Million Opportunities

4. In the Service Quality Gap Model - what is Gap 3?
Used to create frequency distribution tally sheets
The gap between specifications and how service is performed.
Deming.
= yij - y(bar)i --> value minus sum of that treatment (of row)

5. Define durability.
Mean time to replacement.
Lean (or JIT).
A tool that shows the physical flows through a space.
p-bar - the long-run percent defective.

6. What is the center line of a p-chart?
Workers - machines - materials.
Financial - customer - internal process - innovation and learning.
Lean (or JIT).
p-bar - the long-run percent defective.

7. Which type of SPC measurement is more precise - variable or attribute?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
F_alpha - df(tr) - df (error)
Producer risk.
Variable.

8. TWO-DIMENTIONAL SCATTER PLOT
= yij - y(bar)i --> value minus sum of that treatment (of row)
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
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.
The gap between what management thinks customers want and what customers really want.

9. 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?
50%
68%
To manage the Six Sigma project.
False - because each machine will have different natural tolerances.

10. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
To manage the Six Sigma project.
The manager in charge of a process being improved in a Six Sigma project.
To be a member of a Six Sigma project team.
No -- the variation also has to be random and "expected."

11. Name the structure associated with Quality Function Deployment.
Waste.
Critical to quality.
The House of Quality.
Studying firms with the best performance in a particular area.

12. FMEA
A tool that shows where there is waste in a process.
Mean time to failure.
Someone who is consistently against virtually everything.
It looks to minimize the probability of a failure - or to minimize its effects

13. In a regression - what does the coefficient of the intercept tell you
Lower control limit.
Initiated before or at design concept finalization
= yij - y(bar)i --> value minus sum of that treatment (of row)
What the value of the dependent variable is when the independent variable is zero.

14. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
No -- if it is not the same - it can only be worse!
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
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

15. What is CTQ?
To obtain a certain desirable outcome from the process
The gap between what management thinks customers want and the process specifications.
Critical to quality.
F_alpha - df(tr) - df (error)

16. What does Crosby say about benchmarking?
10 for Hazardous without warning 1 for none
Lean is waste reduction - Six Sigma is variation reduction.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

17. What happens to control limits on an SPC chart when sample size is increased?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Shows the temporal flow of activities in a project network.
Mean time to failure.
They move closer to the center line.

18. To what does the Six in Six Sigma relate?
Initiated before or at design concept finalization
Fewer good units to sell - increased variable cost/unit.
To obtain a certain desirable outcome from the process
The target number of standard deviations from the mean for specifications.

19. What is FMEA?
Failure Modes and Effects Analysis
Rapid improvement process.
Central Limit Theorem
Blame.

20. Manual Test for Nomality
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
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
Is what induces the failure
To obtain a certain desirable outcome from the process

21. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
If the Response vs. Levels graph if the response lines are not parallel (crossing)
To do a capability study for a non-centered process.
Define - measure - analyze - design - verify.

22. Disadvantages of DOE

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23. Creating a Run Chart
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The ability of a process to consistently meet customer specifications.
A brainstorming tool that shows the connections between ideas.
The primary operating characteristics of a product.

24. Uses of regression
Producer risk.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Taguchi
QFD

25. What is Value Stream Mapping?
A tool that shows where there is waste in a process.
The gap between what customers expect and the service they receive.
Supplier - input - process - output - customer.
Taguchi

26. Risk Priority Number RPN
Fitness for use.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
They move closer to the center line.
The gap between what management thinks customers want and the process specifications.

27. Stratified defect check sheets
Outside.
Stratify a particular defect type according to logical criteria
Brand image.
To mentor/coach (and sometimes train) black belts.

28. Define aesthetic quality.
Initiated before or at design concept finalization
Pleasing to the senses.
A tool that shows the physical flows through a space.
To mentor/coach (and sometimes train) black belts.

29. What is the formula for the standard deviation of a proportion?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
3.4 (assuming 1.5 sigma shift in the mean)
They move closer to the center line.
=sqrt((p*(1-p)/n)

30. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Brand image.
To obtain a certain desirable outcome from the process
No -- the variation also has to be random and "expected."
Attribute

31. What is an affinity diagram?
Blame.
A brainstorming tool that shows the connections between ideas.
Define - measure - analyze - design - verify.
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

32. Test for Independence
Workers - machines - materials.
Causes that lead to a particular effect.
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
Lower skill requirements - faster - less chance for error.

33. One factor at a time (OFAT)
A descending order-sorted bar chart with a cumulative percentage line.
Prevention and appraisal costs are balanced against internal and external failure.
Observed variation in response is caused by the input
Upper control limit.

34. What quality tool formally incorporates the voice of the customer?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Hold all input variables constant except one. Observe the response as you vary the single input.
What the value of the dependent variable is when the independent variable is zero.
QFD

35. In the Service Quality Gap Model - what is Gap 5?
Scrap - rework - retest - downtime - yield losses - disposition costs.
The gap between what customers expect and the service they receive.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
To be a member of a Six Sigma project team.

36. Defect check sheets
Blame.
Consumer risk.
Different types of defects are listed (used for Pareto chart)
Controlling quality at the source.

37. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
To monitor a process when measurement by variables is used.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
The cycle time required to meet demand.

38. FMEA
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
p-bar - the long-run percent defective.
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

39. In the Service Quality Gap Model - what is Gap 4?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The gap between what is promised and what is delivered.
QFD
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

40. What is muda
Is what induces the failure
Organize ideas into meaningful categories by recognizing their underlying similarity
It's good -- but it's still out of control!
Waste.

41. In a regression - what does the standard error of the estimate tell you?
A tool that shows where there is waste in a process.
Lean (or JIT).
10 if Almost impossible to detect
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

42. Defect location check sheets
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Actual drawings - layouts - maps - etc which show where a defect occurs
The ability of a process to consistently meet customer specifications.
=sqrt(Σ(x-x-bar)^2)/(n-1))

43. What are the three main categories of assignable cause?
Workers - machines - materials.
Supplier - input - process - output - customer.
= 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
False - because each machine will have different natural tolerances.

44. If you can only collect categorical data - what type of SPC charting can you do?
Look for the assignable cause of non-random variation.
A time series plot.
Prevention and appraisal costs are balanced against internal and external failure.
Attribute.

45. Statistical Hypothesis
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
An assertion or conjecture concerning one or more populations
To obtain a certain desirable outcome from the process
Linearity - normality - homoscedasticity - independence.

46. In the Service Quality Gap Model - what is Gap 2?
Hold all input variables constant except one. Observe the response as you vary the single input.
The gap between what management thinks customers want and the process specifications.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Critical to quality.

47. Define conformance quality.
Taguchi
p-bar - the long-run percent defective.
The degree to which a product meets pre-established standards.
Define - measure - analyze - improve - control.

48. Who developed the fishbone diagram?
Kaoru Ishikawa.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Causes that lead to a particular effect.
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

49. Test for constant variance
A tool that shows where there is waste in a process.
Shifts - Trends - Repeating patterns - Correlation with known events
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.
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

50. Define benchmarking.
Studying firms with the best performance in a particular area.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
The ability of a process to consistently meet customer specifications.
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