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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. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Outside.
100%
Lower skill requirements - faster - less chance for error.

2. What is Value Stream Mapping?
3.4 (assuming 1.5 sigma shift in the mean)
A tool that shows where there is waste in a process.
To monitor a process when measurement by variables is used.
Define - measure - analyze - improve - control.

3. Cause and Effect Diagrams
Conformance to specifications.
Method developed by Ishikawa to graphically display the causes of any given problem
Concluding there has not been an effect/change when there has.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

4. Regression Analysis
A tool that shows the physical flows through a space.
It's good -- but it's still out of control!
The gap between what is promised and what is delivered.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

5. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
F_alpha - df(tr) - df (error)
The target number of standard deviations from the mean for 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
Attribute

6. You have been plotting sample means on an x-bar chart and all points indicate normal - expected variation. Is the process in control?

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7. Manual Test for Nomality
A tool that shows the physical flows through a space.
A tool that shows performance along key dimensions all at once.
To monitor a process when measurement by variables is used.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

8. What does DMAIC stand for?
Define - measure - analyze - improve - control.
Mistake-proofing.
= 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
The gap between specifications and how service is performed.

9. What is Type 1 Error?
Concluding there has been an effect/change when there has not.
Is the way in which the failure is manifested.
0.9^3 or 72.9%
Look for the assignable cause of non-random variation.

10. Process occurance ranking
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Consumer risk.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

11. List two components of prevention cost.
0.9^3 or 72.9%
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
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
Conformance to specifications.

12. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Workers - machines - materials.
Failure Modes and Effects Analysis
Lower skill requirements - faster - less chance for error.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

13. What quality tool formally incorporates the voice of the customer?
QFD
=sqrt((p*(1-p)/n)
A scatterplot.
To manage the Six Sigma project.

14. What is a Pareto chart?
Fewer good units to sell - increased variable cost/unit.
Concluding there has been an effect/change when there has not.
The primary operating characteristics of a product.
A descending order-sorted bar chart with a cumulative percentage line.

15. Definition of Interaction
Attribute.
The ability of a process to consistently meet customer specifications.
A brainstorming tool that shows the connections between ideas.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

16. What does the abbreviation LCL stand for?
Lower control limit.
The ability of a process to consistently meet customer specifications.
Mistake-proofing.
5%

17. List two components of internal failure.
Concluding there has been an effect/change when there has not.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Sort - Set in Order - Shine - Standardize - Sustain
The US national quality award.

18. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
=sqrt(Σ(x-x-bar)^2)/(n-1))
Through producer/consumer negotiation.
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
Lean (or JIT).

19. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
To manage the Six Sigma project.
To do a capability study for a non-centered process.

20. Test for constant variance
Fewer good units to sell - increased variable cost/unit.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
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 looks to minimize the probability of a failure - or to minimize its effects

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

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22. Risk Priority Number RPN
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
To be a member of a Six Sigma project team.
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.

23. What is FMEA?
The House of Quality.
Failure Modes and Effects Analysis
Hold all input variables constant except one. Observe the response as you vary the single input.
Initiated before or at design concept finalization

24. In the Service Quality Gap Model - what is Gap 1?
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
No -- only if the process is also capable.
The gap between what management thinks customers want and what customers really want.

25. Define takt time.
The cycle time required to meet demand.
Mistake-proofing.
Inventory = throughput x flow time.
Fishbone - cause-and-effect diagram.

26. What is poka yoke?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
0.9^3 or 72.9%
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Mistake-proofing.

27. What is DMADV?
Define - measure - analyze - design - verify.
To monitor a process when measurement by attribute is used.
Fishbone - cause-and-effect diagram.
Someone who is consistently against virtually everything.

28. What are two other names for an Ishikawa diagram?
Attribute.
Fishbone - cause-and-effect diagram.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Because the mean and standard deviation are independent of each other.

29. What is the role of a black belt?
QFD
Fitness for use.
Rapid improvement process.
To manage the Six Sigma project.

30. Name the structure associated with Quality Function Deployment.
Prevention - appraisal - internal failure - external failure.
The House of Quality.
Observed variation in response is caused by the input
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

31. Who is a process owner?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
A random variable that summarizes the information from the sample(s).
The manager in charge of a process being improved in a Six Sigma project.
QFD

32. Creating a Run Chart
Not necessarily.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Studying firms with the best performance in a particular area.
100%

33. In the Service Quality Gap Model - what is Gap 2?
The gap between what management thinks customers want and what customers really want.
The gap between what management thinks customers want and the process specifications.
To do a capability study for a non-centered process.
Assigns scores to weighted criteria for each project under consideration.

34. Who developed the fishbone diagram?
Kaoru Ishikawa.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
95%

35. When is Cpk used?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
To do a capability study for a non-centered process.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

36. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
68%
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:
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

37. What is the center line of an X-bar chart?
X-bar-bar
Prevention and appraisal costs are balanced against internal and external failure.
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
Large enough to find two of the attribute - on average.

38. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
No -- the variation also has to be random and "expected."
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Through producer/consumer negotiation.
The House of Quality.

39. If a three-stage process has 90% yields at each stage - what is the overall yield?
A random variable that summarizes the information from the sample(s).
Through producer/consumer negotiation.
3.4 (assuming 1.5 sigma shift in the mean)
0.9^3 or 72.9%

40. Explain the difference between technical and functional service quality.
Defects Per Million Opportunities
Technical quality is the "what" of the service; functional quality is the "how."
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).
Fewer good units to sell - increased variable cost/unit.

41. List two components of external failure.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Defects Per Million Opportunities
The gap between what is promised and what is delivered.
Through producer/consumer negotiation.

42. For what is a p-chart used?
To monitor a process when measurement by variables is used.
10 for Hazardous without warning 1 for none
A tool that shows the physical flows through a space.
To monitor a process when measurement by attribute is used.

43. Affinity Diagrams
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
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

44. In Juran's Cost of Quality model - which categories of costs balance which other categories?
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).
False - because each machine will have different natural tolerances.
To monitor a process when measurement by attribute is used.
Prevention and appraisal costs are balanced against internal and external failure.

45. Define durability.
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
Mean time to replacement.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Producer risk.

46. DFMEA
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Inventory = throughput x flow time.
Supplier - input - process - output - customer.
Initiated before or at design concept finalization

47. The Test Statistic (TS)
50%
F_alpha - df(tr) - df (error)
A random variable that summarizes the information from the sample(s).
Prevention - appraisal - internal failure - external failure.

48. What is the Baldrige Award?
Outside.
Critical to quality.
The US national quality award.
X-bar-bar

49. Define features.
To be a member of a Six Sigma project team.
Lean (or JIT).
68%
The secondary characteristics of a product; "bells and whistles."

50. 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?
= yij - y(bar)i --> value minus sum of that treatment (of row)
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
False - because each machine will have different natural tolerances.
Fractional factorial designs (orthogonal arrays)