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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. 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
Technical quality is the "what" of the service; functional quality is the "how."
Brand image.
Lower control limit.

2. Defect check sheets
Different types of defects are listed (used for Pareto chart)
99.73%
Actual drawings - layouts - maps - etc which show where a defect occurs
Mistake-proofing.

3. One factor at a time (OFAT)
Lower control limit.
Fewer good units to sell - increased variable cost/unit.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Hold all input variables constant except one. Observe the response as you vary the single input.

4. Define yield.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The ratio of outputs to inputs; 1-scrap.
68%
The manager in charge of a process being improved in a Six Sigma project.

5. In the Service Quality Gap Model - what is Gap 2?
Through producer/consumer negotiation.
The gap between what management thinks customers want and the process specifications.
Conformance to specifications.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

6. What is muda
Outside.
Waste.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

7. What is a histogram?
Taguchi
Assigns scores to weighted criteria for each project under consideration.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
The ability of a process to consistently meet customer specifications.

8. Risk Priority Number RPN
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
A tool that shows performance along key dimensions all at once.
Central Limit Theorem
Shifts - Trends - Repeating patterns - Correlation with known events

9. What is DMADV?
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Critical to quality.
To obtain a certain desirable outcome from the process
Define - measure - analyze - design - verify.

10. Complete this quality phrase: 'Fix the process - not the _____.'
The manager in charge of a process being improved in a Six Sigma project.
Scrap - rework - retest - downtime - yield losses - disposition costs.
10 if Almost impossible to detect
Blame.

11. What is the center line of an X-bar chart?
No -- the variation also has to be random and "expected."
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
X-bar-bar

12. Name the structure associated with Quality Function Deployment.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Observed variation in response is caused by the input
The gap between specifications and how service is performed.
The House of Quality.

13. Define product reliability.
Used to create frequency distribution tally sheets
The target number of standard deviations from the mean for specifications.
Concluding there has not been an effect/change when there has.
Mean time to failure.

14. Failure Mode
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Is the way in which the failure is manifested.
The House of Quality.
Workers - machines - materials.

15. For what is a p-chart used?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
A time series plot.
To monitor a process when measurement by attribute is used.
Is the consequence of the failure.

16. What is Kaizen?
Taguchi
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.
Method developed by Ishikawa to graphically display the causes of any given problem
Rapid improvement process.

17. DOE
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
X-bar-bar
=sqrt(Σ(x-x-bar)^2)/(n-1))
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

18. What are the four regression assumptions?
Controlling quality at the source.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Linearity - normality - homoscedasticity - independence.
=sqrt(Σ(x-x-bar)^2)/(n-1))

19. What is CTQ?
The cycle time required to meet demand.
Critical to quality.
The gap between what customers expect and the service they receive.
Assigns scores to weighted criteria for each project under consideration.

20. Define performance quality.
Consumer risk.
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).
100%
The primary operating characteristics of a product.

21. ANOVA

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22. Statistical Hypothesis
3.4 (assuming 1.5 sigma shift in the mean)
5%
An assertion or conjecture concerning one or more populations
Used to create frequency distribution tally sheets

23. What quality tool formally incorporates the voice of the customer?
F_alpha - df(tr) - df (error)
Mean time to failure.
Failure Modes and Effects Analysis
QFD

24. List two components of external failure.
3.4 (assuming 1.5 sigma shift in the mean)
Rapid improvement process.
Prevention and appraisal costs are balanced against internal and external failure.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

25. Taguchi's experimental designs are of this type.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
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
Fractional factorial designs (orthogonal arrays)
A random variable that summarizes the information from the sample(s).

26. What is a Gage R&R?
Upper control limit.
It's good -- but it's still out of control!
Hold all input variables constant except one. Observe the response as you vary the single input.
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).

27. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Is the consequence of the failure.
Method developed by Ishikawa to graphically display the causes of any given problem
Lower skill requirements - faster - less chance for error.
Before production starts

28. What are the 5 Ss?
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:
Speed - courtesy - competence - and ease of repair.
Fewer good units to sell - increased variable cost/unit.
Sort - Set in Order - Shine - Standardize - Sustain

29. List two components of prevention cost.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
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.
Central Limit Theorem

30. With Six Sigma capability - how many defects per million opportunities would you see?
Variable.
Conformance to specifications.
3.4 (assuming 1.5 sigma shift in the mean)
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

31. Define features.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
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 Japanese national quality award.
The secondary characteristics of a product; "bells and whistles."

32. What does DMAIC stand for?
Define - measure - analyze - improve - control.
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:
Technical quality is the "what" of the service; functional quality is the "how."
Mean time to failure.

33. List Garvin's eight dimensions of product quality.
Prevention - appraisal - internal failure - external failure.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Because the mean and standard deviation are independent of each other.

34. In a regression - what does the coefficient of the intercept tell you
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Linearity - normality - homoscedasticity - independence.
What the value of the dependent variable is when the independent variable is zero.
10 if Almost impossible to detect

35. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Initiated before or at design concept finalization
Blame.
Sampling for SPC is done real time.
Before production starts

36. What is a Pareto chart?
A scatterplot.
A descending order-sorted bar chart with a cumulative percentage line.
The Japanese national quality award.
Scrap - rework - retest - downtime - yield losses - disposition costs.

37. If you can only collect categorical data - what type of SPC charting can you do?
Hold all input variables constant except one. Observe the response as you vary the single input.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Attribute.
Conformance to specifications.

38. What is poka yoke?
Stratify a particular defect type according to logical criteria
Reliability - Assurance - Responsiveness - Tangibles - Empathy
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.
Mistake-proofing.

39. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Conformance to specifications.
A descending order-sorted bar chart with a cumulative percentage line.
Fishbone - cause-and-effect diagram.

40. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
10 for Hazardous without warning 1 for none
Lean (or JIT).
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 Japanese national quality award.

41. What type of risk is associated with Type II Error?
To mentor/coach (and sometimes train) black belts.
Workers - machines - materials.
Consumer risk.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

42. Process check sheets
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Used to create frequency distribution tally sheets
The cycle time required to meet demand.
Concluding there has not been an effect/change when there has.

43. A process is operating "in control." Does this mean the customer's requirements are met?
Through producer/consumer negotiation.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
No -- only if the process is also capable.
An assertion or conjecture concerning one or more populations

44. What is a spaghetti diagram?
10 if Almost impossible to detect
Blame.
A tool that shows the physical flows through a space.
Define - measure - analyze - design - verify.

45. What is a run chart?
A time series plot.
The House of Quality.
Can't tell without a Range chart.
False - because each machine will have different natural tolerances.

46. To what does the Six in Six Sigma relate?
The target number of standard deviations from the mean for specifications.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
X-bar-bar
Sampling for SPC is done real time.

47. List two components of internal failure.
The degree to which a product meets pre-established standards.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Consumer risk.
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:

48. What is process capability?
Can't tell without a Range chart.
Not necessarily.
The ability of a process to consistently meet customer specifications.
The degree to which a product meets pre-established standards.

49. FMEA
Mean time to replacement.
It looks to minimize the probability of a failure - or to minimize its effects
Financial - customer - internal process - innovation and learning.
Initiated before or at design concept finalization

50. In the Service Quality Gap Model - what is Gap 1?
The gap between what management thinks customers want and what customers really want.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Represents the behavior of a process
A random variable that summarizes the information from the sample(s).