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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 inventory approach contributes to process quality by "lowering the river to find the rocks?"
Central Limit Theorem
Lean (or JIT).
p-bar - the long-run percent defective.
Conformance to specifications.

2. What is a dashboard?
Controlling quality at the source.
A tool that shows performance along key dimensions all at once.
Outside.
Fitness for use.

3. FMEA
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
Is the way in which the failure is manifested.
Lower control limit.
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

4. 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?
p-bar - the long-run percent defective.
False - because each machine will have different natural tolerances.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Different types of defects are listed (used for Pareto chart)

5. What is the difference between the way sampling is done for SPC and for acceptance sampling?
p-bar - the long-run percent defective.
Sampling for SPC is done real time.
QFD
An assertion or conjecture concerning one or more populations

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

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7. Manual Test for Nomality
Lean (or JIT).
The manager in charge of a process being improved in a Six Sigma project.
A random variable that summarizes the information from the sample(s).
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. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
95%
Assigns scores to weighted criteria for each project under consideration.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
3.4 (assuming 1.5 sigma shift in the mean)

9. If a three-stage process has 90% yields at each stage - what is the overall yield?
False - because each machine will have different natural tolerances.
Speed - courtesy - competence - and ease of repair.
Failure Modes and Effects Analysis
0.9^3 or 72.9%

10. Regression Analysis
Kaoru Ishikawa.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
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.

11. Defect location check sheets
Actual drawings - layouts - maps - etc which show where a defect occurs
The US national quality award.
=sqrt((p*(1-p)/n)
50%

12. Pareto Analysis
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Initiated before or at design concept finalization
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).

13. Define benchmarking.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Central Limit Theorem
Actual drawings - layouts - maps - etc which show where a defect occurs
Studying firms with the best performance in a particular area.

14. What is muda
The gap between what management thinks customers want and the process specifications.
Critical to quality.
Waste.
No -- if it is not the same - it can only be worse!

15. What is a histogram?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
X-bar-bar
10 for Hazardous without warning 1 for none
F_alpha - df(tr) - df (error)

16. Taguchi's experimental designs are of this type.
QFD
Through producer/consumer negotiation.
100%
Fractional factorial designs (orthogonal arrays)

17. In the Service Quality Gap Model - what is Gap 4?
A brainstorming tool that shows the connections between ideas.
5%
The gap between what is promised and what is delivered.
Failure Modes and Effects Analysis

18. PFMEA
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Sort - Set in Order - Shine - Standardize - Sustain
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Before production starts

19. What is Type II Error?
The manager in charge of a process being improved in a Six Sigma project.
Concluding there has not been an effect/change when there has.
Studying firms with the best performance in a particular area.
Lean (or JIT).

20. Residual
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Variable.
Method developed by Ishikawa to graphically display the causes of any given problem
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

21. 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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22. Non-random patterns (Run Charts)
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.
Lower control limit.
Shifts - Trends - Repeating patterns - Correlation with known events
Deming.

23. In a regression - what does the standard error of the estimate tell you?
Define - measure - analyze - improve - control.
Lower control limit.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
A tool that shows performance along key dimensions all at once.

24. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Financial - customer - internal process - innovation and learning.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Conformance to specifications.
Attribute.

25. One factor at a time (OFAT)
Observed variation in response is caused by the input
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The secondary characteristics of a product; "bells and whistles."
Is the consequence of the failure.

26. What are the four perspectives of the Balanced Scorecard?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Different types of defects are listed (used for Pareto chart)
Financial - customer - internal process - innovation and learning.
Rapid improvement process.

27. If you have calculated a Cpk - should you also calculate a Cp?
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 scatterplot.
No -- if it is not the same - it can only be worse!
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

28. List two components of external failure.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Mean time to replacement.
To monitor a process when measurement by attribute is used.
The Japanese national quality award.

29. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Attribute
To be a member of a Six Sigma project team.
= 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
Pleasing to the senses.

30. What is poka yoke?
Mistake-proofing.
50%
The primary operating characteristics of a product.
The gap between what is promised and what is delivered.

31. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
Variable.
Shows the temporal flow of activities in a project network.
Speed - courtesy - competence - and ease of repair.

32. What is Little's Law?
Inventory = throughput x flow time.
Through producer/consumer negotiation.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Initiated before or at design concept finalization

33. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Define - measure - analyze - design - verify.
Blame.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Variable.

34. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
=sqrt((p*(1-p)/n)
Method developed by Ishikawa to graphically display the causes of any given problem
Lower skill requirements - faster - less chance for error.
A descending order-sorted bar chart with a cumulative percentage line.

35. What is CTQ?
Before production starts
F_alpha - df(tr) - df (error)
Fewer good units to sell - increased variable cost/unit.
Critical to quality.

36. Define product reliability.
It looks to minimize the probability of a failure - or to minimize its effects
A random variable that summarizes the information from the sample(s).
Lower skill requirements - faster - less chance for error.
Mean time to failure.

37. In Juran's Cost of Quality model - which categories of costs balance which other categories?
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.
They move closer to the center line.
Prevention - appraisal - internal failure - external failure.

38. Disadvantages of DOE

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39. What graphical tool is used to show the relationship between two numerical variables?
Through producer/consumer negotiation.
The gap between what customers expect and the service they receive.
A scatterplot.
Critical to quality.

40. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
A random variable that summarizes the information from the sample(s).
Through producer/consumer negotiation.
A descending order-sorted bar chart with a cumulative percentage line.
99.73%

41. What are the three main categories of assignable cause?
Workers - machines - materials.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
X-bar-bar
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

42. How are LQL and AQL determined in an acceptance sampling plan?
Stratify a particular defect type according to logical criteria
Studying firms with the best performance in a particular area.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Through producer/consumer negotiation.

43. Who first studied randomness in industrial processes
Walter A. Shewhart
Reliability - Assurance - Responsiveness - Tangibles - Empathy
=sqrt((p*(1-p)/n)
A brainstorming tool that shows the connections between ideas.

44. Residual(eij)
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).
Before production starts
= yij - y(bar)i --> value minus sum of that treatment (of row)
Supplier - input - process - output - customer.

45. What is the Baldrige Award?
The US national quality award.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Sampling for SPC is done real time.
50%

46. Regression
Represents the behavior of a process
Define - measure - analyze - design - verify.
Speed - courtesy - competence - and ease of repair.
Lean (or JIT).

47. What is Type 1 Error?
Concluding there has been an effect/change when there has not.
99.73%
Waste.
Mean time to failure.

48. Uses of regression
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The degree to which a product meets pre-established standards.
Lean (or JIT).
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

49. What are the 5 Ss?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Sort - Set in Order - Shine - Standardize - Sustain
No -- only if the process is also capable.
Initiated before or at design concept finalization

50. DFMEA
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
99.73%
Is what induces the failure
Initiated before or at design concept finalization