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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. FMEA
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
The target number of standard deviations from the mean for specifications.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A scatterplot.

2. What is the role of a master black belt?
To mentor/coach (and sometimes train) black belts.
Mean time to failure.
Concluding there has been an effect/change when there has not.
Lower skill requirements - faster - less chance for error.

3. In Juran's Cost of Quality model - which categories of costs balance which other categories?
100%
Prevention and appraisal costs are balanced against internal and external failure.
A time series plot.
Supplier - input - process - output - customer.

4. Define yield.
The ratio of outputs to inputs; 1-scrap.
Define - measure - analyze - design - verify.
No -- the variation also has to be random and "expected."
No -- only if the process is also capable.

5. What is the Deming Prize?
The Japanese national quality award.
A tool that shows performance along key dimensions all at once.
Observed variation in response is caused by the input
Lean is waste reduction - Six Sigma is variation reduction.

6. In the Service Quality Gap Model - what is Gap 1?
To monitor a process when measurement by attribute is used.
Studying firms with the best performance in a particular area.
The US national quality award.
The gap between what management thinks customers want and what customers really want.

7. Failure effect
Is the consequence of the failure.
No -- only if the process is also capable.
Workers - machines - materials.
Causes that lead to a particular effect.

8. Disadvantages of DOE

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9. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Define - measure - analyze - design - verify.
100%
10 for Hazardous without warning 1 for none

10. What percentage of a normal distribution lies above the mean?
50%
Defects Per Million Opportunities
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
A descending order-sorted bar chart with a cumulative percentage line.

11. What are the 5 Ss?
Lower control limit.
A tool that shows the physical flows through a space.
Sort - Set in Order - Shine - Standardize - Sustain
Rapid improvement process.

12. Manual Test for Nomality
The gap between what customers expect and the service they receive.
10 if Almost impossible to detect
The ability of a process to consistently meet customer specifications.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

13. Define aesthetic quality.
X-bar-bar
Pleasing to the senses.
The secondary characteristics of a product; "bells and whistles."
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

14. Define performance quality.
Causes that lead to a particular effect.
The target number of standard deviations from the mean for specifications.
Through producer/consumer negotiation.
The primary operating characteristics of a product.

15. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
p-bar - the long-run percent defective.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Producer risk.
68%

16. What is DMADV?
Lower control limit.
Technical quality is the "what" of the service; functional quality is the "how."
Define - measure - analyze - design - verify.
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

17. What is the 5S model?
A time series plot.
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
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Scrap - rework - retest - downtime - yield losses - disposition costs.

18. Uses of regression
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Lower skill requirements - faster - less chance for error.
QFD
Prevention and appraisal costs are balanced against internal and external failure.

19. What is the formula for standard deviation?
Stratify a particular defect type according to logical criteria
Can't tell without a Range chart.
Fractional factorial designs (orthogonal arrays)
=sqrt(Σ(x-x-bar)^2)/(n-1))

20. Failure cause
A scatterplot.
Is what induces the failure
Sort - Set in Order - Shine - Standardize - Sustain
To be a member of a Six Sigma project team.

21. What is Type 1 Error?
Concluding there has been an effect/change when there has not.
Represents the behavior of a process
The gap between what customers expect and the service they receive.
The gap between what is promised and what is delivered.

22. 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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23. What does Crosby say about benchmarking?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Technical quality is the "what" of the service; functional quality is the "how."
Is what induces the failure
Stratify a particular defect type according to logical criteria

24. List two components of internal failure.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
To manage the Six Sigma project.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Define - measure - analyze - improve - control.

25. Does it ever make sense to accept a job when a process is incapable?
Look for the assignable cause of non-random variation.
Critical to quality.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
A descending order-sorted bar chart with a cumulative percentage line.

26. What graphical tool is used to show the relationship between two numerical variables?
It usually isn't possible to hold all other variables constant - There is no way to account for the effect of joint variation of independent variables - such as interaction - There is no way to account for experimental error - including measurement v
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
A scatterplot.

27. Process occurance ranking
The gap between what management thinks customers want and the process specifications.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Scrap - rework - retest - downtime - yield losses - disposition costs.

28. What is muda
The gap between what management thinks customers want and what customers really want.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Waste.
They move closer to the center line.

29. Explain the difference between technical and functional service quality.
=sqrt(Σ(x-x-bar)^2)/(n-1))
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Mean time to failure.
Technical quality is the "what" of the service; functional quality is the "how."

30. One factor at a time (OFAT)
Observed variation in response is caused by the input
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Sampling for SPC is done real time.
95%

31. Test for Independence
Failure Modes and Effects Analysis
Through producer/consumer negotiation.
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
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

32. What is the center line of an X-bar chart?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
X-bar-bar
To monitor a process when measurement by variables is used.
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).

33. List two components of prevention cost.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
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).
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Sort - Set in Order - Shine - Standardize - Sustain

34. To what does the Six in Six Sigma relate?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Prevention - appraisal - internal failure - external failure.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
The target number of standard deviations from the mean for specifications.

35. What is the difference between Lean and Six Sigma?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The gap between what management thinks customers want and the process specifications.
Financial - customer - internal process - innovation and learning.
Lean is waste reduction - Six Sigma is variation reduction.

36. Which quality guru developed the concept of loss to society?
Initiated before or at design concept finalization
Taguchi
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Financial - customer - internal process - innovation and learning.

37. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Attribute
A scatterplot.
No -- if it is not the same - it can only be worse!
Represents the behavior of a process

38. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
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
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

39. In the Service Quality Gap Model - what is Gap 2?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Lean (or JIT).
Assigns scores to weighted criteria for each project under consideration.
The gap between what management thinks customers want and the process specifications.

40. 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?
Studying firms with the best performance in a particular area.
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
False - because each machine will have different natural tolerances.
99.73%

41. Regression
F_alpha - df(tr) - df (error)
Represents the behavior of a process
To monitor a process when measurement by variables is used.
10 for Hazardous without warning 1 for none

42. What is written on the "spines" of a fishbone diagram?
Causes that lead to a particular effect.
To mentor/coach (and sometimes train) black belts.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
To be a member of a Six Sigma project team.

43. What is poka yoke?
It's good -- but it's still out of control!
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Mistake-proofing.
Central Limit Theorem

44. If you can only collect categorical data - what type of SPC charting can you do?
Is the way in which the failure is manifested.
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
The primary operating characteristics of a product.
Attribute.

45. What is a spaghetti diagram?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
A tool that shows the physical flows through a space.
Prevention - appraisal - internal failure - external failure.
Define - measure - analyze - design - verify.

46. Pareto Analysis
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
A tool that shows performance along key dimensions all at once.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
100%

47. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Failure Modes and Effects Analysis
Walter A. Shewhart
Fishbone - cause-and-effect diagram.
No -- the variation also has to be random and "expected."

48. Detection Criteria Ranking
Reliability - Assurance - Responsiveness - Tangibles - Empathy
The ability of a process to consistently meet customer specifications.
10 if Almost impossible to detect
A time series plot.

49. PFMEA
Lower control limit.
It looks to minimize the probability of a failure - or to minimize its effects
Before production starts
Lower skill requirements - faster - less chance for error.

50. What is process capability?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
The ability of a process to consistently meet customer specifications.
It usually isn't possible to hold all other variables constant - There is no way to account for the effect of joint variation of independent variables - such as interaction - There is no way to account for experimental error - including measurement v
Someone who is consistently against virtually everything.