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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. Who is a process owner?
Hold all input variables constant except one. Observe the response as you vary the single input.
Shifts - Trends - Repeating patterns - Correlation with known events
To manage the Six Sigma project.
The manager in charge of a process being improved in a Six Sigma project.

2. 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!
To mentor/coach (and sometimes train) black belts.
Variable.
Organize ideas into meaningful categories by recognizing their underlying similarity

3. What is DPMO?
QFD
Not necessarily.
Defects Per Million Opportunities
The gap between what is promised and what is delivered.

4. What is a Pareto chart?
They move closer to the center line.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
A descending order-sorted bar chart with a cumulative percentage line.
Large enough to find two of the attribute - on average.

5. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Define - measure - analyze - improve - control.
Lean (or JIT).
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
Look for the assignable cause of non-random variation.

6. What are two other names for an Ishikawa diagram?
The ratio of outputs to inputs; 1-scrap.
Causes that lead to a particular effect.
Fishbone - cause-and-effect diagram.
Before production starts

7. TWO-DIMENTIONAL SCATTER PLOT
Lean (or JIT).
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
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 simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

8. Define yield.
The ratio of outputs to inputs; 1-scrap.
Central Limit Theorem
Hold all input variables constant except one. Observe the response as you vary the single input.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

9. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Brand image.
Attribute
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.

10. One factor at a time (OFAT)
Initiated before or at design concept finalization
No -- only if the process is also capable.
Hold all input variables constant except one. Observe the response as you vary the single input.
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

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

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12. What does SIPOC stand for?
Sort - Set in Order - Shine - Standardize - Sustain
Supplier - input - process - output - customer.
Conformance to specifications.
3.4 (assuming 1.5 sigma shift in the mean)

13. When is Cpk used?
To do a capability study for a non-centered process.
Define - measure - analyze - improve - control.
No -- the variation also has to be random and "expected."
Lower skill requirements - faster - less chance for error.

14. Affinity Diagrams
Lean (or JIT).
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Hold all input variables constant except one. Observe the response as you vary the single input.
Lower control limit.

15. What happens to control limits on an SPC chart when sample size is increased?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
They move closer to the center line.
50%

16. What is the center line of a p-chart?
= yij - y(bar)i --> value minus sum of that treatment (of row)
QFD
p-bar - the long-run percent defective.
Failure Modes and Effects Analysis

17. Which quality guru developed the concept of loss to society?
A tool that shows the physical flows through a space.
10 if Almost impossible to detect
Taguchi
Upper control limit.

18. Presence of interaction effect
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Mean time to failure.
A tool that shows the physical flows through a space.
95%

19. What is the formula for standard deviation?
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).
=sqrt(Σ(x-x-bar)^2)/(n-1))
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
Mean time to failure.

20. If you have calculated a Cpk - should you also calculate a Cp?
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.
The Japanese national quality award.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

21. What are the 5 Ss?
Sort - Set in Order - Shine - Standardize - Sustain
A descending order-sorted bar chart with a cumulative percentage line.
A diagram that shows the relationships between activities in a project network.
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

22. Define perceived quality (Garvin's framework).
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
The House of Quality.
Brand image.
To mentor/coach (and sometimes train) black belts.

23. What do you do when a process is out of control?
Defects Per Million Opportunities
Define - measure - analyze - design - verify.
Look for the assignable cause of non-random variation.
3.4 (assuming 1.5 sigma shift in the mean)

24. Process check sheets
Look for the assignable cause of non-random variation.
Fitness for use.
Used to create frequency distribution tally sheets
To manage the Six Sigma project.

25. Regression
Taguchi
A random variable that summarizes the information from the sample(s).
Someone who is consistently against virtually everything.
Represents the behavior of a process

26. Definition of Interaction
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Blame.
Fishbone - cause-and-effect diagram.
Concluding there has been an effect/change when there has not.

27. What is an affinity diagram?
A brainstorming tool that shows the connections between ideas.
Controlling quality at the source.
The target number of standard deviations from the mean for specifications.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

28. Define benchmarking.
Walter A. Shewhart
Studying firms with the best performance in a particular area.
Because the mean and standard deviation are independent of each other.
F_alpha - df(tr) - df (error)

29. Name the structure associated with Quality Function Deployment.
It looks to minimize the probability of a failure - or to minimize its effects
No -- the variation also has to be random and "expected."
What the value of the dependent variable is when the independent variable is zero.
The House of Quality.

30. Test for Independence
3.4 (assuming 1.5 sigma shift in the mean)
Lean (or JIT).
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
=sqrt((p*(1-p)/n)

31. What is a dashboard?
Variable.
To manage the Six Sigma project.
A tool that shows performance along key dimensions all at once.
Concluding there has not been an effect/change when there has.

32. What size should samples be for attribute SPC?
Large enough to find two of the attribute - on average.
Scrap - rework - retest - downtime - yield losses - disposition costs.
95%
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

33. What does the abbreviation LCL stand for?
Fewer good units to sell - increased variable cost/unit.
p-bar - the long-run percent defective.
To obtain a certain desirable outcome from the process
Lower control limit.

34. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
An assertion or conjecture concerning one or more populations
Speed - courtesy - competence - and ease of repair.
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. 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.
100%
Kaoru Ishikawa.
Hold all input variables constant except one. Observe the response as you vary the single input.

36. Histogram by Hand
Workers - machines - materials.
Studying firms with the best performance in a particular area.
Assigns scores to weighted criteria for each project under consideration.
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

37. What is a Gantt chart?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Financial - customer - internal process - innovation and learning.
Define - measure - analyze - improve - control.
Shows the temporal flow of activities in a project network.

38. What quality tool formally incorporates the voice of the customer?
To mentor/coach (and sometimes train) black belts.
QFD
To obtain a certain desirable outcome from the process
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

39. What percentage of a normal distribution lies above the mean?
Rapid improvement process.
Attribute
F_alpha - df(tr) - df (error)
50%

40. What is the 5S model?
Lower skill requirements - faster - less chance for error.
Outside.
p-bar - the long-run percent defective.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

41. Failure Mode
Conformance to specifications.
Is the way in which the failure is manifested.
Waste.
Fractional factorial designs (orthogonal arrays)

42. A process is operating "in control." Does this mean the customer's requirements are met?
5%
Financial - customer - internal process - innovation and learning.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
No -- only if the process is also capable.

43. What is written on the "spines" of a fishbone diagram?
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:
95%
Walter A. Shewhart
Causes that lead to a particular effect.

44. Stratified defect check sheets
Lean is waste reduction - Six Sigma is variation reduction.
Deming.
Stratify a particular defect type according to logical criteria
The Japanese national quality award.

45. Defect location check sheets
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
Actual drawings - layouts - maps - etc which show where a defect occurs
False - because each machine will have different natural tolerances.
Define - measure - analyze - design - verify.

46. If a three-stage process has 90% yields at each stage - what is the overall yield?
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).
Because the mean and standard deviation are independent of each other.
0.9^3 or 72.9%
It looks to minimize the probability of a failure - or to minimize its effects

47. What are the three main categories of assignable cause?
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
Is what induces the failure
The House of Quality.
Workers - machines - materials.

48. What is Value Stream Mapping?
Stratify a particular defect type according to logical criteria
Waste.
A tool that shows where there is waste in a process.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

49. In a regression - what does the standard error of the estimate tell you?
To do a capability study for a non-centered process.
Sort - Set in Order - Shine - Standardize - Sustain
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The target number of standard deviations from the mean for specifications.

50. 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.
Workers - machines - materials.
Walter A. Shewhart
It looks to minimize the probability of a failure - or to minimize its effects