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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 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
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Organize ideas into meaningful categories by recognizing their underlying similarity
Attribute

2. For what is an x-bar chart used?
The gap between what management thinks customers want and what customers really want.
68%
To monitor a process when measurement by variables is used.
Producer risk.

3. Disadvantages of DOE

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4. What is a dashboard?
Financial - customer - internal process - innovation and learning.
To do a capability study for a non-centered process.
A tool that shows performance along key dimensions all at once.
Can't tell without a Range chart.

5. What is written on the "spines" of a fishbone diagram?
Controlling quality at the source.
Because the mean and standard deviation are independent of each other.
Pleasing to the senses.
Causes that lead to a particular effect.

6. Creating a Run Chart
95%
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

7. If you can only collect categorical data - what type of SPC charting can you do?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Inventory = throughput x flow time.
Fewer good units to sell - increased variable cost/unit.
Attribute.

8. Name the structure associated with Quality Function Deployment.
The Japanese national quality award.
A tool that shows where there is waste in a process.
The House of Quality.
Controlling quality at the source.

9. 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?
99.73%
Speed - courtesy - competence - and ease of repair.
False - because each machine will have different natural tolerances.
Attribute

10. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Define - measure - analyze - design - verify.
Attribute
The degree to which a product meets pre-established standards.
The gap between what management thinks customers want and the process specifications.

11. Define features.
Lean is waste reduction - Six Sigma is variation reduction.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
The secondary characteristics of a product; "bells and whistles."
Lower skill requirements - faster - less chance for error.

12. Define yield.
Attribute.
Attribute
The ratio of outputs to inputs; 1-scrap.
Brand image.

13. Regression
Mean time to failure.
Failure Modes and Effects Analysis
The gap between what customers expect and the service they receive.
Represents the behavior of a process

14. What is a CAVE man?
50%
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Someone who is consistently against virtually everything.
=sqrt(Σ(x-x-bar)^2)/(n-1))

15. Regression Analysis
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
100%
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Someone who is consistently against virtually everything.

16. What are the four regression assumptions?
Mean time to failure.
Used to create frequency distribution tally sheets
Linearity - normality - homoscedasticity - independence.
Financial - customer - internal process - innovation and learning.

17. Define takt time.
Someone who is consistently against virtually everything.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
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:
The cycle time required to meet demand.

18. Define durability.
A brainstorming tool that shows the connections between ideas.
Define - measure - analyze - improve - control.
Mean time to replacement.
Used to create frequency distribution tally sheets

19. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
95%
A time series plot.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

20. Uses of regression
To mentor/coach (and sometimes train) black belts.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Brand image.
A tool that shows the physical flows through a space.

21. What is Value Stream Mapping?
3.4 (assuming 1.5 sigma shift in the mean)
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
The House of Quality.
A tool that shows where there is waste in a process.

22. TWO-DIMENTIONAL SCATTER PLOT
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Fractional factorial designs (orthogonal arrays)
Kaoru Ishikawa.
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

23. Process check sheets
Variable.
The number of standard deviations some value is from the mean.
Linearity - normality - homoscedasticity - independence.
Used to create frequency distribution tally sheets

24. Presence of interaction effect
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).
68%
Used to create frequency distribution tally sheets
If the Response vs. Levels graph if the response lines are not parallel (crossing)

25. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Different types of defects are listed (used for Pareto chart)
Conformance to specifications.
Outside.
A random variable that summarizes the information from the sample(s).

26. Stratified defect check sheets
A scatterplot.
Method developed by Ishikawa to graphically display the causes of any given problem
Stratify a particular defect type according to logical criteria
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

27. Non-random patterns (Run Charts)
Shifts - Trends - Repeating patterns - Correlation with known events
No -- only if the process is also capable.
5%
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

28. Residual
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Assigns scores to weighted criteria for each project under consideration.

29. What is FMEA?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Failure Modes and Effects Analysis
100%
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

30. If a three-stage process has 90% yields at each stage - what is the overall yield?
Mean time to failure.
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
0.9^3 or 72.9%
5%

31. ANOVA

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32. List two components of external failure.
QFD
100%
A descending order-sorted bar chart with a cumulative percentage line.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

33. Test for Independence
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
Is the consequence of the failure.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

34. List two components of internal failure.
Workers - machines - materials.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Variable.
Concluding there has been an effect/change when there has not.

35. What quality guru emphasizes management as a system?
False - because each machine will have different natural tolerances.
To monitor a process when measurement by attribute is used.
=sqrt((p*(1-p)/n)
Deming.

36. What is the Baldrige Award?
The number of standard deviations some value is from the mean.
The US national quality award.
Controlling quality at the source.
Is the consequence of the failure.

37. Does it ever make sense to accept a job when a process is incapable?
Is the way in which the failure is manifested.
68%
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

38. What is DPMO?
Scrap - rework - retest - downtime - yield losses - disposition costs.
Defects Per Million Opportunities
Pleasing to the senses.
Lower control limit.

39. Cause and Effect Diagrams
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
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
Method developed by Ishikawa to graphically display the causes of any given problem
Lower skill requirements - faster - less chance for error.

40. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Assigns scores to weighted criteria for each project under consideration.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Not necessarily.
Variable.

41. Who is a process owner?
Actual drawings - layouts - maps - etc which show where a defect occurs
Outside.
Fractional factorial designs (orthogonal arrays)
The manager in charge of a process being improved in a Six Sigma project.

42. Histogram by Hand
Different types of defects are listed (used for Pareto chart)
Observed variation in response is caused by the input
Taguchi
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

43. 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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44. Manual Test for Nomality
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
To monitor a process when measurement by attribute is used.
The manager in charge of a process being improved in a Six Sigma project.
Large enough to find two of the attribute - on average.

45. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Lean (or JIT).
Organize ideas into meaningful categories by recognizing their underlying similarity
It looks to minimize the probability of a failure - or to minimize its effects
99.73%

46. Define aesthetic quality.
Supplier - input - process - output - customer.
Outside.
Pleasing to the senses.
= 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

47. Definition of Interaction
Workers - machines - materials.
Define - measure - analyze - design - verify.
Critical to quality.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

48. One factor at a time (OFAT)
Observed variation in response is caused by the input
Fitness for use.
Walter A. Shewhart
Conformance to specifications.

49. What are the four perspectives of the Balanced Scorecard?
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
Hold all input variables constant except one. Observe the response as you vary the single input.
Stratify a particular defect type according to logical criteria
Financial - customer - internal process - innovation and learning.

50. In the Service Quality Gap Model - what is Gap 2?
The gap between what management thinks customers want and the process specifications.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
The degree to which a product meets pre-established standards.
95%