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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. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Waste.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Mean time to failure.
95%

2. When is Cpk used?
The manager in charge of a process being improved in a Six Sigma project.
68%
To do a capability study for a non-centered process.
Can't tell without a Range chart.

3. Creating a Run Chart
Taguchi
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The target number of standard deviations from the mean for specifications.
50%

4. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Failure Modes and Effects Analysis
What the value of the dependent variable is when the independent variable is zero.

5. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
= yij - y(bar)i --> value minus sum of that treatment (of row)
The target number of standard deviations from the mean for specifications.
10 for Hazardous without warning 1 for none
5%

6. ANOVA

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7. What is Type II Error?
The Japanese national quality award.
=sqrt((p*(1-p)/n)
Concluding there has been an effect/change when there has not.
Concluding there has not been an effect/change when there has.

8. Which type of SPC measurement is more precise - variable or attribute?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
What the value of the dependent variable is when the independent variable is zero.
QFD
Variable.

9. Effect ranking (Severity of the Defect)
10 for Hazardous without warning 1 for none
The gap between specifications and how service is performed.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

10. What is the difference between Lean and Six Sigma?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
The number of standard deviations some value is from the mean.
A scatterplot.
Lean is waste reduction - Six Sigma is variation reduction.

11. Define benchmarking.
Studying firms with the best performance in a particular area.
Actual drawings - layouts - maps - etc which show where a defect occurs
Is the way in which the failure is manifested.
Mistake-proofing.

12. Regression Analysis
Controlling quality at the source.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Fractional factorial designs (orthogonal arrays)
Waste.

13. What is CTQ?
Speed - courtesy - competence - and ease of repair.
Critical to quality.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Prevention - appraisal - internal failure - external failure.

14. To what does the Six in Six Sigma relate?
The Japanese national quality award.
It looks to minimize the probability of a failure - or to minimize its effects
The target number of standard deviations from the mean for specifications.
95%

15. Definition of Interaction
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
To manage the Six Sigma project.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
To monitor a process when measurement by variables is used.

16. List Garvin's eight dimensions of product quality.
Sampling for SPC is done real time.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Someone who is consistently against virtually everything.
The US national quality award.

17. What are the four categories of costs in Juran's framework?
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
Prevention - appraisal - internal failure - external failure.
Deming.
Used to create frequency distribution tally sheets

18. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
3.4 (assuming 1.5 sigma shift in the mean)
Lean is waste reduction - Six Sigma is variation reduction.
The gap between what management thinks customers want and what customers really want.

19. Name the structure associated with Quality Function Deployment.
To obtain a certain desirable outcome from the process
Different types of defects are listed (used for Pareto chart)
The House of Quality.
Causes that lead to a particular effect.

20. What happens to control limits on an SPC chart when sample size is increased?
Outside.
They move closer to the center line.
To obtain a certain desirable outcome from the process
100%

21. Complete this quality phrase: 'Fix the process - not the _____.'
A time series plot.
Lower skill requirements - faster - less chance for error.
Look for the assignable cause of non-random variation.
Blame.

22. What is the difference between the way sampling is done for SPC and for acceptance sampling?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
= yij - y(bar)i --> value minus sum of that treatment (of row)
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

23. What are the three main categories of assignable cause?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Conformance to specifications.
Studying firms with the best performance in a particular area.
Workers - machines - materials.

24. Who is a process owner?
Failure Modes and Effects Analysis
The manager in charge of a process being improved in a Six Sigma project.
= y = Beta(0) + Beta(1)X + epsilon y=dependent variable (response) x=independent variable (predictor of y) - epsilon=error component - Beta(not)=intersection. If data include zero - it represents the mean of the distribution of y when - x=0. It does
Prevention and appraisal costs are balanced against internal and external failure.

25. What is muda
Through producer/consumer negotiation.
Waste.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
A tool that shows performance along key dimensions all at once.

26. In the Service Quality Gap Model - what is Gap 2?
5%
Taguchi
To obtain a certain desirable outcome from the process
The gap between what management thinks customers want and the process specifications.

27. Define features.
Initiated before or at design concept finalization
3.4 (assuming 1.5 sigma shift in the mean)
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 secondary characteristics of a product; "bells and whistles."

28. What type of risk is associated with Type 1 Error?
Producer risk.
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
Prevention and appraisal costs are balanced against internal and external failure.
= y = Beta(0) + Beta(1)X + epsilon y=dependent variable (response) x=independent variable (predictor of y) - epsilon=error component - Beta(not)=intersection. If data include zero - it represents the mean of the distribution of y when - x=0. It does

29. What is poka yoke?
Mistake-proofing.
X-bar-bar
Blame.
Attribute.

30. Does it ever make sense to accept a job when a process is incapable?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Causes that lead to a particular effect.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Critical to quality.

31. What graphical tool is used to show the relationship between two numerical variables?
Technical quality is the "what" of the service; functional quality is the "how."
A scatterplot.
Sort - Set in Order - Shine - Standardize - Sustain
The ability of a process to consistently meet customer specifications.

32. If you have calculated a Cpk - should you also calculate a Cp?
Outside.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Blame.
Controlling quality at the source.

33. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Concluding there has not been an effect/change when there has.
Attribute
A tool that shows performance along key dimensions all at once.
A brainstorming tool that shows the connections between ideas.

34. What is the 5S model?
A descending order-sorted bar chart with a cumulative percentage line.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Define - measure - analyze - improve - control.
No -- if it is not the same - it can only be worse!

35. Affinity Diagrams
Organize ideas into meaningful categories by recognizing their underlying similarity
Not necessarily.
Define - measure - analyze - improve - control.
Shows the temporal flow of activities in a project network.

36. What is DMADV?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
The secondary characteristics of a product; "bells and whistles."
The gap between what is promised and what is delivered.
Define - measure - analyze - design - verify.

37. What is a run chart?
A time series plot.
Supplier - input - process - output - customer.
Defects Per Million Opportunities
Deming.

38. What is a Pareto chart?
Lean is waste reduction - Six Sigma is variation reduction.
Fitness for use.
A descending order-sorted bar chart with a cumulative percentage line.
Fractional factorial designs (orthogonal arrays)

39. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
To be a member of a Six Sigma project team.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Blame.

40. What is a spaghetti diagram?
A scatterplot.
Pleasing to the senses.
A tool that shows the physical flows through a space.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

41. What does Crosby say about benchmarking?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Studying firms with the best performance in a particular area.
The degree to which a product meets pre-established standards.

42. Presence of interaction effect
To do a capability study for a non-centered process.
Lean is waste reduction - Six Sigma is variation reduction.
It's good -- but it's still out of control!
If the Response vs. Levels graph if the response lines are not parallel (crossing)

43. In the Service Quality Gap Model - what is Gap 5?
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).
If the Response vs. Levels graph if the response lines are not parallel (crossing)
The gap between what customers expect and the service they receive.
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

44. DOE
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).
Conformance to specifications.
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
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

45. What is the center line of a p-chart?
p-bar - the long-run percent defective.
A random variable that summarizes the information from the sample(s).
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
It's good -- but it's still out of control!

46. What is Jidoka?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Walter A. Shewhart
Controlling quality at the source.
Prevention and appraisal costs are balanced against internal and external failure.

47. Non-random patterns (Run Charts)
Hold all input variables constant except one. Observe the response as you vary the single input.
Is what induces the failure
=sqrt((p*(1-p)/n)
Shifts - Trends - Repeating patterns - Correlation with known events

48. Detection Criteria Ranking
10 if Almost impossible to detect
Look for the assignable cause of non-random variation.
Producer risk.
An assertion or conjecture concerning one or more populations

49. If a Cp shows that a process is not capable - should you calculate Cpk?
Brand image.
0.9^3 or 72.9%
No -- if it is not the same - it can only be worse!
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.

50. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
It's good -- but it's still out of control!
No -- the variation also has to be random and "expected."
Through producer/consumer negotiation.
Linearity - normality - homoscedasticity - independence.