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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. Cause and Effect Diagrams
Variable.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Someone who is consistently against virtually everything.
Method developed by Ishikawa to graphically display the causes of any given problem

2. Who developed the fishbone diagram?
Kaoru Ishikawa.
Central Limit Theorem
A brainstorming tool that shows the connections between ideas.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

3. For what is an x-bar chart used?
Mistake-proofing.
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
To monitor a process when measurement by variables is used.
Fractional factorial designs (orthogonal arrays)

4. Define aesthetic quality.
Studying firms with the best performance in a particular area.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Pleasing to the senses.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

5. In Juran's Cost of Quality model - which categories of costs balance which other categories?
The Japanese national quality award.
Prevention and appraisal costs are balanced against internal and external failure.
A random variable that summarizes the information from the sample(s).
Fractional factorial designs (orthogonal arrays)

6. Which type of SPC measurement is more precise - variable or attribute?
Variable.
Concluding there has not been an effect/change when there has.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
A tool that shows where there is waste in a process.

7. What are the Five Dimensions of Service Quality?
10 if Almost impossible to detect
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Represents the behavior of a process
=sqrt(Σ(x-x-bar)^2)/(n-1))

8. DFMEA
10 if Almost impossible to detect
Assigns scores to weighted criteria for each project under consideration.
Initiated before or at design concept finalization
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

9. What is the Baldrige Award?
The US national quality award.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
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
3.4 (assuming 1.5 sigma shift in the mean)

10. What is a network diagram?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Initiated before or at design concept finalization
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
A diagram that shows the relationships between activities in a project network.

11. What is process capability?
Linearity - normality - homoscedasticity - independence.
The ability of a process to consistently meet customer specifications.
False - because each machine will have different natural tolerances.
50%

12. What are the four categories of costs in Juran's framework?
The Japanese national quality award.
Large enough to find two of the attribute - on average.
Prevention - appraisal - internal failure - external failure.
It's good -- but it's still out of control!

13. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Outside.
Consumer risk.
To monitor a process when measurement by variables is used.
Pleasing to the senses.

14. If a Cp shows that a process is not capable - should you calculate Cpk?
Lean is waste reduction - Six Sigma is variation reduction.
Central Limit Theorem
The gap between what is promised and what is delivered.
No -- if it is not the same - it can only be worse!

15. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
The ability of a process to consistently meet customer specifications.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Blame.
Lean (or JIT).

16. What is an affinity diagram?
X-bar-bar
Defects Per Million Opportunities
p-bar - the long-run percent defective.
A brainstorming tool that shows the connections between ideas.

17. In a regression - what does the p value of F tell you?
The gap between what management thinks customers want and what customers really want.
To be a member of a Six Sigma project team.
0.9^3 or 72.9%
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).

18. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
F_alpha - df(tr) - df (error)
Mistake-proofing.
Concluding there has been an effect/change when there has not.
No -- the variation also has to be random and "expected."

19. Affinity Diagrams
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Organize ideas into meaningful categories by recognizing their underlying similarity
Concluding there has been an effect/change when there has not.
Define - measure - analyze - improve - control.

20. What is a Gage R&R?
Large enough to find two of the attribute - on average.
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).
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
3.4 (assuming 1.5 sigma shift in the mean)

21. What is a run chart?
p-bar - the long-run percent defective.
F_alpha - df(tr) - df (error)
A time series plot.
The House of Quality.

22. Definition of Interaction
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
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Kaoru Ishikawa.

23. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
To mentor/coach (and sometimes train) black belts.
The House of Quality.
The cycle time required to meet demand.

24. What is the role of a green belt?
Lean is waste reduction - Six Sigma is variation reduction.
Is the way in which the failure is manifested.
To be a member of a Six Sigma project team.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

25. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
=sqrt((p*(1-p)/n)
Supplier - input - process - output - customer.
Concluding there has been an effect/change when there has not.

26. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Conformance to specifications.
To monitor a process when measurement by variables is used.
68%

27. What is a Pareto chart?
A descending order-sorted bar chart with a cumulative percentage line.
Because the mean and standard deviation are independent of each other.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Is the consequence of the failure.

28. Statistical Hypothesis
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
An assertion or conjecture concerning one or more populations
Critical to quality.
Blame.

29. In the Service Quality Gap Model - what is Gap 5?
The gap between what customers expect and the service they receive.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
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

30. Process occurance ranking
Variable.
Can't tell without a Range chart.
Observed variation in response is caused by the input
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

31. Failure cause
Is what induces the failure
Not necessarily.
To manage the Six Sigma project.
Stratify a particular defect type according to logical criteria

32. What graphical tool is used to show the relationship between two numerical variables?
99.73%
A scatterplot.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Used to create frequency distribution tally sheets

33. What quality guru emphasizes management as a system?
Define - measure - analyze - improve - control.
10 if Almost impossible to detect
Large enough to find two of the attribute - on average.
Deming.

34. Detection Criteria Ranking
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
10 if Almost impossible to detect
Lower control limit.
Concluding there has been an effect/change when there has not.

35. What are the 5 Ss?
Sort - Set in Order - Shine - Standardize - Sustain
Controlling quality at the source.
=sqrt((p*(1-p)/n)
3.4 (assuming 1.5 sigma shift in the mean)

36. What is written on the "spines" of a fishbone diagram?
To manage the Six Sigma project.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Causes that lead to a particular effect.
The number of standard deviations some value is from the mean.

37. Define features.
=sqrt((p*(1-p)/n)
False - because each machine will have different natural tolerances.
The secondary characteristics of a product; "bells and whistles."
10 for Hazardous without warning 1 for none

38. What is DMADV?
Define - measure - analyze - design - verify.
Someone who is consistently against virtually everything.
The target number of standard deviations from the mean for specifications.
50%

39. Process check sheets
X-bar-bar
Used to create frequency distribution tally sheets
A time series plot.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

40. What is the center line of a p-chart?
p-bar - the long-run percent defective.
Taguchi
Blame.
The ratio of outputs to inputs; 1-scrap.

41. What size should samples be for attribute SPC?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Large enough to find two of the attribute - on average.
The cycle time required to meet demand.

42. When yields decrease - what are the two effects on contribution?
Waste.
Large enough to find two of the attribute - on average.
Fewer good units to sell - increased variable cost/unit.
Upper control limit.

43. What is Type II Error?
Shifts - Trends - Repeating patterns - Correlation with known events
To be a member of a Six Sigma project team.
Fishbone - cause-and-effect diagram.
Concluding there has not been an effect/change when there has.

44. Advantages of DOE
Lower control limit.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
The primary operating characteristics of a product.
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

45. Your production process meets customer specifications. Is your process in control?
100%
Outside.
Not necessarily.
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).

46. Define takt time.
The cycle time required to meet demand.
Is the consequence of the failure.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Lower control limit.

47. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
100%
The ability of a process to consistently meet customer specifications.

48. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The gap between what management thinks customers want and what customers really want.
Lower skill requirements - faster - less chance for error.
Taguchi

49. Disadvantages of DOE

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50. What is muda
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Workers - machines - materials.
Waste.
A brainstorming tool that shows the connections between ideas.