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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. Defect check sheets
An assertion or conjecture concerning one or more populations
Outside.
Different types of defects are listed (used for Pareto chart)
Sort - Set in Order - Shine - Standardize - Sustain

2. Test for constant variance
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
The US national quality award.
Fractional factorial designs (orthogonal arrays)
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.

3. What is Type II Error?
Sampling for SPC is done real time.
Technical quality is the "what" of the service; functional quality is the "how."
No -- the variation also has to be random and "expected."
Concluding there has not been an effect/change when there has.

4. A process is operating "in control." Does this mean the customer's requirements are met?
Outside.
No -- only if the process is also capable.
Stratify a particular defect type according to logical criteria
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

5. 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.
To manage the Six Sigma project.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Prevention and appraisal costs are balanced against internal and external failure.

6. What is a dashboard?
0.9^3 or 72.9%
The manager in charge of a process being improved in a Six Sigma project.
A tool that shows performance along key dimensions all at once.
Failure Modes and Effects Analysis

7. What happens to control limits on an SPC chart when sample size is increased?
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
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.
They move closer to the center line.

8. Define benchmarking.
Brand image.
The ratio of outputs to inputs; 1-scrap.
The House of Quality.
Studying firms with the best performance in a particular area.

9. With Six Sigma capability - how many defects per million opportunities would you see?
3.4 (assuming 1.5 sigma shift in the mean)
Pleasing to the senses.
The US national quality award.
Used to create frequency distribution tally sheets

10. Why do you need two control charts for variables SPC?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Because the mean and standard deviation are independent of each other.
Walter A. Shewhart
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

11. What type of risk is associated with Type 1 Error?
= yij - y(bar)i --> value minus sum of that treatment (of row)
Concluding there has not been an effect/change when there has.
Producer risk.
Technical quality is the "what" of the service; functional quality is the "how."

12. Effect ranking (Severity of the Defect)
10 for Hazardous without warning 1 for none
Conformance to specifications.
Prevention and appraisal costs are balanced against internal and external failure.
Failure Modes and Effects Analysis

13. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
95%
Sort - Set in Order - Shine - Standardize - Sustain
A tool that shows the physical flows through a space.

14. How does Juran define quality?
The manager in charge of a process being improved in a Six Sigma project.
The degree to which a product meets pre-established standards.
The gap between specifications and how service is performed.
Fitness for use.

15. What is the center line of an X-bar chart?
The gap between what customers expect and the service they receive.
X-bar-bar
Define - measure - analyze - improve - control.
Causes that lead to a particular effect.

16. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
Workers - machines - materials.
Is the way in which the failure is manifested.
Through producer/consumer negotiation.

17. Cause and Effect Diagrams
The US national quality award.
X-bar-bar
Method developed by Ishikawa to graphically display the causes of any given problem
Can't tell without a Range chart.

18. Does it ever make sense to accept a job when a process is incapable?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Failure Modes and Effects Analysis
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
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:

19. Define durability.
A tool that shows where there is waste in a process.
Mean time to replacement.
=sqrt((p*(1-p)/n)
The gap between what customers expect and the service they receive.

20. Stratified defect check sheets
Deming.
Fewer good units to sell - increased variable cost/unit.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Stratify a particular defect type according to logical criteria

21. What are the Five Dimensions of Service Quality?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Lean is waste reduction - Six Sigma is variation reduction.
To mentor/coach (and sometimes train) black belts.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

22. When yields decrease - what are the two effects on contribution?
Hold all input variables constant except one. Observe the response as you vary the single input.
Fewer good units to sell - increased variable cost/unit.
The manager in charge of a process being improved in a Six Sigma project.
The ability of a process to consistently meet customer specifications.

23. TWO-DIMENTIONAL SCATTER PLOT
The gap between what management thinks customers want and the process specifications.
To obtain a certain desirable outcome from the process
Linearity - normality - homoscedasticity - independence.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

24. What is the role of a green belt?
Because the mean and standard deviation are independent of each other.
To be a member of a Six Sigma project team.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
To mentor/coach (and sometimes train) black belts.

25. The Test Statistic (TS)
The gap between what management thinks customers want and what customers really want.
Mean time to failure.
A random variable that summarizes the information from the sample(s).
Is the consequence of the failure.

26. What is the role of a master black belt?
Define - measure - analyze - improve - control.
Concluding there has been an effect/change when there has not.
To mentor/coach (and sometimes train) black belts.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

27. In a regression - what does the p value of F tell you?
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).
The cycle time required to meet demand.
10 if Almost impossible to detect
It's good -- but it's still out of control!

28. What is the Baldrige Award?
A tool that shows the physical flows through a space.
The US national quality award.
Defects Per Million Opportunities
Blame.

29. Definition of Interaction
Attribute
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
To do a capability study for a non-centered process.
Lower skill requirements - faster - less chance for error.

30. Statistical Hypothesis
Conformance to specifications.
Brand image.
To be a member of a Six Sigma project team.
An assertion or conjecture concerning one or more populations

31. What is the 5S model?
To do a capability study for a non-centered process.
Workers - machines - materials.
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
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

32. In a regression - what does the coefficient of the intercept tell you
What the value of the dependent variable is when the independent variable is zero.
Blame.
Is the way in which the failure is manifested.
To mentor/coach (and sometimes train) black belts.

33. PFMEA
Before production starts
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
68%
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

34. Presence of interaction effect
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)
If the Response vs. Levels graph if the response lines are not parallel (crossing)
To do a capability study for a non-centered process.

35. What are the three main categories of assignable cause?
99.73%
Workers - machines - materials.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Used to create frequency distribution tally sheets

36. 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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37. Advantages of DOE
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
=sqrt((p*(1-p)/n)
Technical quality is the "what" of the service; functional quality is the "how."
To obtain a certain desirable outcome from the process

38. List two components of external failure.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Look for the assignable cause of non-random variation.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

39. Affinity Diagrams
Walter A. Shewhart
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
3.4 (assuming 1.5 sigma shift in the mean)
=sqrt((p*(1-p)/n)

40. What are the four regression assumptions?
Walter A. Shewhart
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Linearity - normality - homoscedasticity - independence.
To do a capability study for a non-centered process.

41. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
Lean (or JIT).
=sqrt((p*(1-p)/n)
A random variable that summarizes the information from the sample(s).

42. ANOVA

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43. List Garvin's eight dimensions of product quality.
To obtain a certain desirable outcome from the process
Consumer risk.
To be a member of a Six Sigma project team.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

44. What does the abbreviation LCL stand for?
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
Lean (or JIT).
Lower control limit.
Blame.

45. What is FMEA?
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
Failure Modes and Effects Analysis
Sampling for SPC is done real time.
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

46. Taguchi's experimental designs are of this type.
The primary operating characteristics of a product.
Fractional factorial designs (orthogonal arrays)
The House of Quality.
Is the way in which the failure is manifested.

47. FMEA
Fitness for use.
10 for Hazardous without warning 1 for none
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
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

48. For what is a p-chart used?
Mean time to replacement.
To monitor a process when measurement by attribute is used.
Critical to quality.
To manage the Six Sigma project.

49. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
The number of standard deviations some value is from the mean.
Studying firms with the best performance in a particular area.
Lower skill requirements - faster - less chance for error.
Causes that lead to a particular effect.

50. What is DPMO?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Defects Per Million Opportunities
Failure Modes and Effects Analysis
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables