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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. What percentage of a normal distribution lies above the mean?
Actual drawings - layouts - maps - etc which show where a defect occurs
50%
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).
Workers - machines - materials.

2. Define yield.
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
QFD
To monitor a process when measurement by attribute is used.
The ratio of outputs to inputs; 1-scrap.

3. Simple Regression Analysis (one factor regression model)
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
The gap between what management thinks customers want and what customers really want.
= 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 ratio of outputs to inputs; 1-scrap.

4. If a three-stage process has 90% yields at each stage - what is the overall yield?
50%
0.9^3 or 72.9%
Lean is waste reduction - Six Sigma is variation reduction.
Concluding there has not been an effect/change when there has.

5. Complete this quality phrase: 'Fix the process - not the _____.'
Prevention - appraisal - internal failure - external failure.
The number of standard deviations some value is from the mean.
Blame.
The ability of a process to consistently meet customer specifications.

6. Uses of regression - Control
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.
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
Outside.
To obtain a certain desirable outcome from the process

7. List two appraisal costs.
False - because each machine will have different natural tolerances.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The cycle time required to meet demand.
Fitness for use.

8. For what is an x-bar chart used?
10 for Hazardous without warning 1 for none
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
To monitor a process when measurement by variables is used.
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

9. What is an affinity diagram?
Defects Per Million Opportunities
Walter A. Shewhart
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
A brainstorming tool that shows the connections between ideas.

10. Define product reliability.
Attribute.
Mean time to 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
Sampling for SPC is done real time.

11. Definition of Interaction
To be a member of a Six Sigma project team.
3.4 (assuming 1.5 sigma shift in the mean)
Causes that lead to a particular effect.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

12. What is the Deming Prize?
Large enough to find two of the attribute - on average.
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
A tool that shows performance along key dimensions all at once.
The Japanese national quality award.

13. What is Jidoka?
The primary operating characteristics of a product.
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.
Controlling quality at the source.

14. Failure cause
Is what induces the failure
Controlling quality at the source.
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
No -- if it is not the same - it can only be worse!

15. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Look for the assignable cause of non-random variation.
68%
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Concluding there has been an effect/change when there has not.

16. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
Financial - customer - internal process - innovation and learning.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
No -- only if the process is also capable.

17. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
The target number of standard deviations from the mean for specifications.
Method developed by Ishikawa to graphically display the causes of any given problem
Conformance to specifications.
What the value of the dependent variable is when the independent variable is zero.

18. For what is a p-chart used?
5%
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.
To monitor a process when measurement by attribute is used.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

19. Daniel Test
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
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:
A descending order-sorted bar chart with a cumulative percentage line.
The primary operating characteristics of a product.

20. ANOVA

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21. If you have calculated a Cpk - should you also calculate a Cp?
Used to create frequency distribution tally sheets
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Is the consequence of the failure.

22. Regression Analysis
Workers - machines - materials.
Attribute
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The gap between specifications and how service is performed.

23. Stratified defect check sheets
The manager in charge of a process being improved in a Six Sigma project.
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.
Stratify a particular defect type according to logical criteria
Large enough to find two of the attribute - on average.

24. Define durability.
Before production starts
No -- the variation also has to be random and "expected."
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Mean time to replacement.

25. What is FMEA?
Consumer risk.
Inventory = throughput x flow time.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Failure Modes and Effects Analysis

26. What quality guru emphasizes management as a system?
A descending order-sorted bar chart with a cumulative percentage line.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
10 if Almost impossible to detect
Deming.

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

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28. Failure effect
To do a capability study for a non-centered process.
Is the consequence of the failure.
Method developed by Ishikawa to graphically display the causes of any given problem
Reliability - Assurance - Responsiveness - Tangibles - Empathy

29. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
Define - measure - analyze - design - verify.
Organize ideas into meaningful categories by recognizing their underlying similarity
5%
100%

30. To what does the Six in Six Sigma relate?
Before production starts
Outside.
Upper control limit.
The target number of standard deviations from the mean for specifications.

31. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
10 for Hazardous without warning 1 for none
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Prevention and appraisal costs are balanced against internal and external failure.

32. Name the structure associated with Quality Function Deployment.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Workers - machines - materials.
Upper control limit.
The House of Quality.

33. What is a Pareto chart?
A descending order-sorted bar chart with a cumulative percentage line.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Deming.
Variable.

34. What is the formula for the standard deviation of a proportion?
To obtain a certain desirable outcome from the process
Kaoru Ishikawa.
=sqrt((p*(1-p)/n)
Central Limit Theorem

35. Process check sheets
The gap between what management thinks customers want and the process specifications.
The gap between what is promised and what is delivered.
Controlling quality at the source.
Used to create frequency distribution tally sheets

36. Taguchi's experimental designs are of this type.
Fractional factorial designs (orthogonal arrays)
No -- the variation also has to be random and "expected."
= 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 tool that shows the physical flows through a space.

37. Your production process meets customer specifications. Is your process in control?
Not necessarily.
Consumer risk.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
No -- only if the process is also capable.

38. Define perceived quality (Garvin's framework).
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The House of Quality.
Mean time to replacement.
Brand image.

39. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Fishbone - cause-and-effect diagram.
Attribute
The manager in charge of a process being improved in a Six Sigma project.
Taguchi

40. Define conformance quality.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The degree to which a product meets pre-established standards.
Pleasing to the senses.
Supplier - input - process - output - customer.

41. What is muda
50%
A tool that shows the physical flows through a space.
Waste.
Actual drawings - layouts - maps - etc which show where a defect occurs

42. The Test Statistic (TS)
Variable.
A random variable that summarizes the information from the sample(s).
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
Technical quality is the "what" of the service; functional quality is the "how."

43. Define benchmarking.
Studying firms with the best performance in a particular area.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The Japanese national quality award.
The cycle time required to meet demand.

44. In the Service Quality Gap Model - what is Gap 1?
The US national quality award.
Sampling for SPC is done real time.
Lean (or JIT).
The gap between what management thinks customers want and what customers really want.

45. DFMEA
Initiated before or at design concept finalization
F_alpha - df(tr) - df (error)
Through producer/consumer negotiation.
Central Limit Theorem

46. One factor at a time (OFAT)
Reliability - Assurance - Responsiveness - Tangibles - Empathy
The Japanese national quality award.
Walter A. Shewhart
Hold all input variables constant except one. Observe the response as you vary the single input.

47. With Six Sigma capability - how many defects per million opportunities would you see?
99.73%
Speed - courtesy - competence - and ease of repair.
3.4 (assuming 1.5 sigma shift in the mean)
Deming.

48. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
No -- the variation also has to be random and "expected."
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

49. 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.
The gap between what customers expect and the service they receive.
=sqrt(Σ(x-x-bar)^2)/(n-1))
To monitor a process when measurement by attribute is used.

50. What quality tool formally incorporates the voice of the customer?
X-bar-bar
=sqrt(Σ(x-x-bar)^2)/(n-1))
Sampling for SPC is done real time.
QFD