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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
Because the mean and standard deviation are independent of each other.
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
=sqrt((p*(1-p)/n)
Initiated before or at design concept finalization

2. Test for Independence
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
Organize ideas into meaningful categories by recognizing their underlying similarity
Observed variation in response is caused by the input
50%

3. Stratified defect check sheets
Waste.
Stratify a particular defect type according to logical criteria
Workers - machines - materials.
Speed - courtesy - competence - and ease of repair.

4. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Variable.
The manager in charge of a process being improved in a Six Sigma project.
10 if Almost impossible to detect
Pleasing to the senses.

5. What is Type II Error?
Organize ideas into meaningful categories by recognizing their underlying similarity
Concluding there has not been an effect/change when there has.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Taguchi

6. Manual Test for Nomality
Fractional factorial designs (orthogonal arrays)
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Fishbone - cause-and-effect diagram.

7. Affinity Diagrams
Organize ideas into meaningful categories by recognizing their underlying similarity
The ability of a process to consistently meet customer specifications.
Look for the assignable cause of non-random variation.
To monitor a process when measurement by variables is used.

8. Taguchi's experimental designs are of this type.
Fractional factorial designs (orthogonal arrays)
Mistake-proofing.
The ratio of outputs to inputs; 1-scrap.
Lean (or JIT).

9. What does the abbreviation LCL stand for?
A descending order-sorted bar chart with a cumulative percentage line.
Lower control limit.
The gap between specifications and how service is performed.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

10. Residual
The ratio of outputs to inputs; 1-scrap.
3.4 (assuming 1.5 sigma shift in the mean)
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

11. Define product reliability.
Mean time to failure.
Represents the behavior of a process
Variable.
0.9^3 or 72.9%

12. If you can only collect categorical data - what type of SPC charting can you do?
Before production starts
Define - measure - analyze - improve - control.
Attribute.
A tool that shows the physical flows through a space.

13. Creating a Run Chart
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
10 if Almost impossible to detect
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
To manage the Six Sigma project.

14. What is a Gage R&R?
Scrap - rework - retest - downtime - yield losses - disposition costs.
The House of Quality.
Observed variation in response is caused by the 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).

15. What is a CAVE man?
Concluding there has not been an effect/change when there has.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Someone who is consistently against virtually everything.
Supplier - input - process - output - customer.

16. The data points on an SPC p-chart of defective percent plot below the mean. Is this good or bad?

17. If you have calculated a Cpk - should you also calculate a Cp?
Represents the behavior of a process
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
No -- only if the process is also capable.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

18. In a regression - what does the p value of F tell you?
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
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
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).
Lower skill requirements - faster - less chance for error.

19. For what is a p-chart used?
To monitor a process when measurement by attribute is used.
It's good -- but it's still out of control!
Brand image.
Is the consequence of the failure.

20. F value
No -- the variation also has to be random and "expected."
The degree to which a product meets pre-established standards.
F_alpha - df(tr) - df (error)
Method developed by Ishikawa to graphically display the causes of any given problem

21. Histogram by Hand
QFD
Kaoru Ishikawa.
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
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

22. In a regression - what does the standard error of the estimate tell you?
Concluding there has been an effect/change when there has not.
Sort - Set in Order - Shine - Standardize - Sustain
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
10 for Hazardous without warning 1 for none

23. What are the three main categories of assignable cause?
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).
Workers - machines - materials.
To be a member of a Six Sigma project team.
Is the consequence of the failure.

24. Define conformance quality.
Variable.
The degree to which a product meets pre-established standards.
Prevention and appraisal costs are balanced against internal and external failure.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

25. What is a run chart?
Critical to quality.
A time series plot.
Is the way in which the failure is manifested.
The gap between what management thinks customers want and the process specifications.

26. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
A descending order-sorted bar chart with a cumulative percentage line.
Causes that lead to a particular effect.
Define - measure - analyze - design - verify.
95%

27. What are the four categories of costs in Juran's framework?
Prevention - appraisal - internal failure - external failure.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Large enough to find two of the attribute - on average.
Lower control limit.

28. What is FMEA?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Upper control limit.
Failure Modes and Effects Analysis
Walter A. Shewhart

29. What is Jidoka?
Different types of defects are listed (used for Pareto chart)
Controlling quality at the source.
The gap between specifications and how service is performed.
95%

30. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Blame.
A tool that shows where there is waste in a process.
Outside.
68%

31. Define durability.
Causes that lead to a particular effect.
Mean time to replacement.
Lean is waste reduction - Six Sigma is variation reduction.
The gap between what is promised and what is delivered.

32. Statistical Hypothesis
False - because each machine will have different natural tolerances.
An assertion or conjecture concerning one or more populations
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

33. TWO-DIMENTIONAL SCATTER PLOT
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:
A tool that shows performance along key dimensions all at once.
To mentor/coach (and sometimes train) black belts.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

34. In the Service Quality Gap Model - what is Gap 1?
The gap between what management thinks customers want and what customers really want.
F_alpha - df(tr) - df (error)
Fishbone - cause-and-effect diagram.
Deming.

35. In a Z table - what is Z?
The degree to which a product meets pre-established standards.
Brand image.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The number of standard deviations some value is from the mean.

36. What is the 5S model?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Mean time to failure.
Lean (or JIT).

37. Regression
A random variable that summarizes the information from the sample(s).
Represents the behavior of a process
To do a capability study for a non-centered process.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

38. What is CTQ?
Critical to quality.
Concluding there has not been an effect/change when there has.
The gap between what management thinks customers want and the process specifications.
Walter A. Shewhart

39. If a three-stage process has 90% yields at each stage - what is the overall yield?
0.9^3 or 72.9%
Financial - customer - internal process - innovation and learning.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Inventory = throughput x flow time.

40. What is written on the "spines" of a fishbone diagram?
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
Causes that lead to a particular effect.
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
To do a capability study for a non-centered process.

41. Uses of regression
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
To do a capability study for a non-centered process.
Speed - courtesy - competence - and ease of repair.
Financial - customer - internal process - innovation and learning.

42. FMEA
Controlling quality at the source.
It looks to minimize the probability of a failure - or to minimize its effects
Walter A. Shewhart
Hold all input variables constant except one. Observe the response as you vary the single input.

43. DFMEA
A random variable that summarizes the information from the sample(s).
Attribute.
The gap between what customers expect and the service they receive.
Initiated before or at design concept finalization

44. What is a dashboard?
A tool that shows performance along key dimensions all at once.
Pleasing to the senses.
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
Fishbone - cause-and-effect diagram.

45. Failure cause
Variable.
To manage the Six Sigma project.
Is what induces the failure
Fewer good units to sell - increased variable cost/unit.

46. 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.
Actual drawings - layouts - maps - etc which show where a defect occurs
p-bar - the long-run percent defective.
Lean is waste reduction - Six Sigma is variation reduction.

47. What is the role of a black belt?
The number of standard deviations some value is from the mean.
To manage the Six Sigma project.
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).
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

48. If a Cp shows that a process is not capable - should you calculate Cpk?
No -- if it is not the same - it can only be worse!
The US national quality award.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
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

49. 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.
To monitor a process when measurement by variables is used.
Financial - customer - internal process - innovation and learning.
A tool that shows the physical flows through a space.

50. Daniel Test
To do a capability study for a non-centered process.
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:
95%
Attribute.