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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. List two components of prevention cost.
A tool that shows where there is waste in a process.
Large enough to find two of the attribute - on average.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
To obtain a certain desirable outcome from the process

2. Affinity Diagrams
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Hold all input variables constant except one. Observe the response as you vary the single input.
No -- only if the process is also capable.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

3. What is FMEA?
50%
Failure Modes and Effects Analysis
The target number of standard deviations from the mean for specifications.
Shows the temporal flow of activities in a project network.

4. Daniel Test
False - because each machine will have different natural tolerances.
A tool that shows where there is waste in a process.
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:
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

5. What is the center line of an X-bar chart?
Producer risk.
Before production starts
Define - measure - analyze - improve - control.
X-bar-bar

6. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Conformance to specifications.
Lower skill requirements - faster - less chance for error.
99.73%
Supplier - input - process - output - customer.

7. In the Service Quality Gap Model - what is Gap 2?
The gap between what management thinks customers want and the process specifications.
Actual drawings - layouts - maps - etc which show where a defect occurs
Technical quality is the "what" of the service; functional quality is the "how."
Sort - Set in Order - Shine - Standardize - Sustain

8. What is written on the "spines" of a fishbone diagram?
0.9^3 or 72.9%
Causes that lead to a particular effect.
It's good -- but it's still out of control!
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

9. In a Z table - what is Z?
50%
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
A descending order-sorted bar chart with a cumulative percentage line.
The number of standard deviations some value is from the mean.

10. What does Crosby say about benchmarking?
Lower skill requirements - faster - less chance for error.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A time series plot.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

11. Which type of SPC measurement is more precise - variable or attribute?
Pleasing to the senses.
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.
Variable.
Actual drawings - layouts - maps - etc which show where a defect occurs

12. Define yield.
Shifts - Trends - Repeating patterns - Correlation with known events
F_alpha - df(tr) - df (error)
Workers - machines - materials.
The ratio of outputs to inputs; 1-scrap.

13. Risk Priority Number RPN
Concluding there has not been an effect/change when there has.
Financial - customer - internal process - innovation and learning.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Observed variation in response is caused by the input

14. What are the four categories of costs in Juran's framework?
Prevention - appraisal - internal failure - external failure.
Pleasing to the senses.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
p-bar - the long-run percent defective.

15. What percentage of a normal distribution lies above the mean?
50%
The secondary characteristics of a product; "bells and whistles."
Brand image.
The gap between what customers expect and the service they receive.

16. What is the role of a master black belt?
Define - measure - analyze - improve - control.
Defects Per Million Opportunities
It's good -- but it's still out of control!
To mentor/coach (and sometimes train) black belts.

17. Define takt time.
= 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 cycle time required to meet demand.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The ability of a process to consistently meet customer specifications.

18. What is an affinity diagram?
Lean is waste reduction - Six Sigma is variation reduction.
Can't tell without a Range chart.
A brainstorming tool that shows the connections between ideas.
To do a capability study for a non-centered process.

19. For what is a p-chart used?
Attribute
To monitor a process when measurement by attribute is used.
Failure Modes and Effects Analysis
A diagram that shows the relationships between activities in a project network.

20. What is a run chart?
To manage the Six Sigma project.
Shifts - Trends - Repeating patterns - Correlation with known events
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
A time series plot.

21. What is the formula for the standard deviation of a proportion?
Upper control limit.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
=sqrt((p*(1-p)/n)
50%

22. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
5%
Lean is waste reduction - Six Sigma is variation reduction.
False - because each machine will have different natural tolerances.

23. When yields decrease - what are the two effects on contribution?
The ability of a process to consistently meet customer specifications.
Fewer good units to sell - increased variable cost/unit.
Critical to quality.
Central Limit Theorem

24. Test for Independence
A tool that shows the physical flows through a space.
Attribute.
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
p-bar - the long-run percent defective.

25. Disadvantages of DOE

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26. What is the Deming Prize?
The Japanese national quality award.
Upper control limit.
Attribute
A tool that shows the physical flows through a space.

27. What is a network diagram?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
A diagram that shows the relationships between activities in a project network.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
68%

28. What is Jidoka?
Controlling quality at the source.
Someone who is consistently against virtually everything.
Sort - Set in Order - Shine - Standardize - Sustain
To monitor a process when measurement by variables is used.

29. Failure cause
Defects Per Million Opportunities
Mean time to failure.
The primary operating characteristics of a product.
Is what induces the failure

30. PFMEA
X-bar-bar
Before production starts
It's good -- but it's still out of control!
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

31. Process occurance ranking
Consumer risk.
Shifts - Trends - Repeating patterns - Correlation with known events
Attribute
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

32. What is a CAVE man?
Kaoru Ishikawa.
Someone who is consistently against virtually everything.
= 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
Defects Per Million Opportunities

33. What does the abbreviation LCL stand for?
A brainstorming tool that shows the connections between ideas.
Through producer/consumer negotiation.
Lower control limit.
Scrap - rework - retest - downtime - yield losses - disposition costs.

34. FMEA
Represents the behavior of a process
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
Used to create frequency distribution tally sheets
68%

35. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Supplier - input - process - output - customer.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
No -- the variation also has to be random and "expected."
99.73%

36. What type of risk is associated with Type II Error?
Observed variation in response is caused by the input
Consumer risk.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
The number of standard deviations some value is from the mean.

37. What does a project prioritization matrix do?
Assigns scores to weighted criteria for each project under consideration.
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.
Define - measure - analyze - improve - control.

38. Cause and Effect Diagrams
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Method developed by Ishikawa to graphically display the causes of any given problem
The target number of standard deviations from the mean for specifications.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

39. When is Cpk used?
The ratio of outputs to inputs; 1-scrap.
Controlling quality at the source.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
To do a capability study for a non-centered process.

40. Who first studied randomness in industrial processes
Is the consequence of the failure.
To monitor a process when measurement by attribute is used.
Walter A. Shewhart
The House of Quality.

41. Taguchi's experimental designs are of this type.
The ratio of outputs to inputs; 1-scrap.
A brainstorming tool that shows the connections between ideas.
Fractional factorial designs (orthogonal arrays)
The Japanese national quality award.

42. Complete this quality phrase: 'Fix the process - not the _____.'
Blame.
To monitor a process when measurement by attribute is used.
Central Limit Theorem
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

43. To what does the Six in Six Sigma relate?
QFD
The target number of standard deviations from the mean for specifications.
Fewer good units to sell - increased variable cost/unit.
The manager in charge of a process being improved in a Six Sigma project.

44. What is a Pareto chart?
A diagram that shows the relationships between activities in a project network.
A descending order-sorted bar chart with a cumulative percentage line.
To monitor a process when measurement by attribute is used.
The number of standard deviations some value is from the mean.

45. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Prevention and appraisal costs are balanced against internal and external failure.
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 brainstorming tool that shows the connections between ideas.
= yij - y(bar)i --> value minus sum of that treatment (of row)

46. What is CTQ?
Hold all input variables constant except one. Observe the response as you vary the single input.
Critical to quality.
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
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

47. What are two other names for an Ishikawa diagram?
Fishbone - cause-and-effect diagram.
Variable.
Is what induces the failure
Because the mean and standard deviation are independent of each other.

48. Regression
A time series plot.
Prevention - appraisal - internal failure - external failure.
Mean time to failure.
Represents the behavior of a process

49. What are the 5 Ss?
Is the way in which the failure is manifested.
Sort - Set in Order - Shine - Standardize - Sustain
99.73%
Brand image.

50. What is Type II Error?
Concluding there has not been an effect/change when there has.
Linearity - normality - homoscedasticity - independence.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Used to create frequency distribution tally sheets