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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 is the formula for the standard deviation of a proportion?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Lean is waste reduction - Six Sigma is variation reduction.
=sqrt((p*(1-p)/n)
Fewer good units to sell - increased variable cost/unit.

2. What is Jidoka?
A diagram that shows the relationships between activities in a project network.
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.
The target number of standard deviations from the mean for specifications.
Controlling quality at the source.

3. Define aesthetic quality.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Failure Modes and Effects Analysis
Pleasing to the senses.
Lean is waste reduction - Six Sigma is variation reduction.

4. If a three-stage process has 90% yields at each stage - what is the overall yield?
Concluding there has not been an effect/change when there has.
No -- the variation also has to be random and "expected."
A descending order-sorted bar chart with a cumulative percentage line.
0.9^3 or 72.9%

5. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Lean (or JIT).
The primary operating characteristics of a product.
A tool that shows the physical flows through a space.
Sampling for SPC is done real time.

6. In a regression - what does the coefficient of the intercept tell you
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
What the value of the dependent variable is when the independent variable is zero.
Is the consequence of the failure.
10 if Almost impossible to detect

7. What percentage of a normal distribution lies above the mean?
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
Because the mean and standard deviation are independent of each other.
50%
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

8. What graphical tool is used to show the relationship between two numerical variables?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
A scatterplot.
Shifts - Trends - Repeating patterns - Correlation with known events

9. List two components of prevention cost.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Lower control limit.
Causes that lead to a particular effect.

10. Cause and Effect Diagrams
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).
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Method developed by Ishikawa to graphically display the causes of any given problem

11. Explain the difference between technical and functional service quality.
Linearity - normality - homoscedasticity - independence.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Through producer/consumer negotiation.
Technical quality is the "what" of the service; functional quality is the "how."

12. In the Service Quality Gap Model - what is Gap 1?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
The gap between what management thinks customers want and what customers really want.
Outside.
Shows the temporal flow of activities in a project network.

13. What is the Deming Prize?
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
=sqrt((p*(1-p)/n)
The Japanese national quality award.
To be a member of a Six Sigma project team.

14. Failure Mode
Financial - customer - internal process - innovation and learning.
Is the way in which the failure is manifested.
Rapid improvement process.
Variable.

15. Who developed the fishbone diagram?
The Japanese national quality award.
Kaoru Ishikawa.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

16. What is DMADV?
Define - measure - analyze - design - verify.
10 for Hazardous without warning 1 for none
X-bar-bar
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

17. Define durability.
It's good -- but it's still out of control!
Mean time to replacement.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Lean (or JIT).

18. Who first studied randomness in industrial processes
It's good -- but it's still out of control!
Deming.
3.4 (assuming 1.5 sigma shift in the mean)
Walter A. Shewhart

19. What does a project prioritization matrix do?
Variable.
Not necessarily.
Assigns scores to weighted criteria for each project under consideration.
The degree to which a product meets pre-established standards.

20. What type of risk is associated with Type II Error?
Consumer risk.
Technical quality is the "what" of the service; functional quality is the "how."
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:
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

21. 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.
The gap between what management thinks customers want and what customers really want.
The Japanese national quality award.
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.

22. Definition of Interaction
Workers - machines - materials.
Prevention and appraisal costs are balanced against internal and external failure.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Consumer risk.

23. What is CTQ?
Critical to quality.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Is what induces the failure
Hold all input variables constant except one. Observe the response as you vary the single input.

24. What quality tool formally incorporates the voice of the customer?
Attribute
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
QFD
It looks to minimize the probability of a failure - or to minimize its effects

25. Regression
The gap between what management thinks customers want and what customers really want.
Large enough to find two of the attribute - on average.
Represents the behavior of a process
Kaoru Ishikawa.

26. List two components of internal failure.
Walter A. Shewhart
Scrap - rework - retest - downtime - yield losses - disposition costs.
To mentor/coach (and sometimes train) black belts.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

27. What are the four categories of costs in Juran's framework?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
X-bar-bar
Prevention - appraisal - internal failure - external failure.
Speed - courtesy - competence - and ease of repair.

28. What do you do when a process is out of control?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
0.9^3 or 72.9%
Look for the assignable cause of non-random variation.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

29. Who is a process owner?
Pleasing to the senses.
The manager in charge of a process being improved in a Six Sigma project.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Producer risk.

30. What are the 5 Ss?
To obtain a certain desirable outcome from the process
Sort - Set in Order - Shine - Standardize - Sustain
Financial - customer - internal process - innovation and learning.
To mentor/coach (and sometimes train) black belts.

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

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32. If a Cp shows that a process is not capable - should you calculate Cpk?
Defects Per Million Opportunities
Define - measure - analyze - improve - control.
No -- if it is not the same - it can only be worse!
QFD

33. Process occurance ranking
Mean time to replacement.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Financial - customer - internal process - innovation and learning.
Inventory = throughput x flow time.

34. Histogram by Hand
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
68%
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
95%

35. Uses of regression - Control
Look for the assignable cause of non-random variation.
To obtain a certain desirable outcome from the process
Prevention - appraisal - internal failure - external failure.
Financial - customer - internal process - innovation and learning.

36. What is process capability?
The ability of a process to consistently meet customer specifications.
Not necessarily.
Because the mean and standard deviation are independent of each other.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

37. If you can only collect categorical data - what type of SPC charting can you do?
Attribute.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
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
=sqrt((p*(1-p)/n)

38. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Inventory = throughput x flow time.
Attribute
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Sort - Set in Order - Shine - Standardize - Sustain

39. Defect check sheets
Consumer risk.
Different types of defects are listed (used for Pareto chart)
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
A random variable that summarizes the information from the sample(s).

40. What are the four regression assumptions?
The number of standard deviations some value is from the mean.
Linearity - normality - homoscedasticity - independence.
Variable.
100%

41. Residual(eij)
Variable.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
= yij - y(bar)i --> value minus sum of that treatment (of row)
Outside.

42. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Fewer good units to sell - increased variable cost/unit.
The US national quality award.
Outside.
Attribute.

43. Effect ranking (Severity of the Defect)
Concluding there has been an effect/change when there has not.
10 for Hazardous without warning 1 for none
Stratify a particular defect type according to logical criteria
Brand image.

44. Manual Test for Nomality
10 for Hazardous without warning 1 for none
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.
Fitness for use.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

45. Failure effect
They move closer to the center line.
Is the consequence of the failure.
Linearity - normality - homoscedasticity - independence.
Studying firms with the best performance in a particular area.

46. Presence of interaction effect
p-bar - the long-run percent defective.
Attribute.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Represents the behavior of a process

47. What does SIPOC stand for?
Inventory = throughput x flow time.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Technical quality is the "what" of the service; functional quality is the "how."
Supplier - input - process - output - customer.

48. Statistical Hypothesis
No -- only if the process is also capable.
An assertion or conjecture concerning one or more populations
Method developed by Ishikawa to graphically display the causes of any given problem
Assigns scores to weighted criteria for each project under consideration.

49. DFMEA
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
Initiated before or at design concept finalization
The ability of a process to consistently meet customer specifications.
Linearity - normality - homoscedasticity - independence.

50. What is Type 1 Error?
Prevention - appraisal - internal failure - external failure.
Upper control limit.
Concluding there has been an effect/change when there has not.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"