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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. What is Type 1 Error?
Concluding there has been an effect/change when there has not.
Is the way in which the failure is manifested.
The manager in charge of a process being improved in a Six Sigma project.
Sampling for SPC is done real time.

2. What happens to control limits on an SPC chart when sample size is increased?
Lower control limit.
They move closer to the center line.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
It's good -- but it's still out of control!

3. Taguchi's experimental designs are of this type.
Lower skill requirements - faster - less chance for error.
10 for Hazardous without warning 1 for none
Fractional factorial designs (orthogonal arrays)
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

4. Defect check sheets
Different types of defects are listed (used for Pareto chart)
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
Defects Per Million Opportunities
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

5. What quality tool formally incorporates the voice of the customer?
Variable.
QFD
Pleasing to the senses.
To monitor a process when measurement by variables is used.

6. Process occurance ranking
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Concluding there has been an effect/change when there has not.
10 for Hazardous without warning 1 for none

7. Definition of Interaction
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Used to create frequency distribution tally sheets
It looks to minimize the probability of a failure - or to minimize its effects
Scrap - rework - retest - downtime - yield losses - disposition costs.

8. Residual(eij)
The US national quality award.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
A scatterplot.
= yij - y(bar)i --> value minus sum of that treatment (of row)

9. Based on what principal can we use the normal distribution assumptions for SPC?
Consumer risk.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
The number of standard deviations some value is from the mean.
Central Limit Theorem

10. When is Cpk used?
Concluding there has been an effect/change when there has not.
To do a capability study for a non-centered process.
Walter A. Shewhart
The gap between what management thinks customers want and the process specifications.

11. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Lower skill requirements - faster - less chance for error.
Sort - Set in Order - Shine - Standardize - Sustain
Mistake-proofing.
Conformance to specifications.

12. Define benchmarking.
Causes that lead to a particular effect.
Lean (or JIT).
Stratify a particular defect type according to logical criteria
Studying firms with the best performance in a particular area.

13. Who first studied randomness in industrial processes
Walter A. Shewhart
Shifts - Trends - Repeating patterns - Correlation with known events
Variable.
Because the mean and standard deviation are independent of each other.

14. When yields decrease - what are the two effects on contribution?
Speed - courtesy - competence - and ease of repair.
To monitor a process when measurement by variables is used.
A descending order-sorted bar chart with a cumulative percentage line.
Fewer good units to sell - increased variable cost/unit.

15. List Garvin's eight dimensions of product quality.
No -- only if the process is also capable.
The manager in charge of a process being improved in a Six Sigma project.
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

16. What is written on the "spines" of a fishbone diagram?
To monitor a process when measurement by variables is used.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Sort - Set in Order - Shine - Standardize - Sustain
Causes that lead to a particular effect.

17. In the Service Quality Gap Model - what is Gap 4?
Lean is waste reduction - Six Sigma is variation reduction.
The gap between what is promised and what is delivered.
The gap between what customers expect and the service they receive.
Speed - courtesy - competence - and ease of repair.

18. To what does the Six in Six Sigma relate?
The target number of standard deviations from the mean for specifications.
To monitor a process when measurement by variables is used.
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
Consumer risk.

19. In the Service Quality Gap Model - what is Gap 2?
The gap between what management thinks customers want and the process specifications.
Define - measure - analyze - design - verify.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

20. Histogram by Hand
10 for Hazardous without warning 1 for none
Rapid improvement process.
X-bar-bar
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

21. Affinity Diagrams
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Someone who is consistently against virtually everything.
Technical quality is the "what" of the service; functional quality is the "how."
Lean (or JIT).

22. What are the Five Dimensions of Service Quality?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Controlling quality at the source.
68%
= 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

23. Explain the difference between technical and functional service quality.
Inventory = throughput x flow time.
Technical quality is the "what" of the service; functional quality is the "how."
Supplier - input - process - output - customer.
Is the way in which the failure is manifested.

24. What is the role of a green belt?
Define - measure - analyze - improve - control.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Before production starts
To be a member of a Six Sigma project team.

25. In a Z table - what is Z?
To be a member of a Six Sigma project team.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The number of standard deviations some value is from the mean.
A random variable that summarizes the information from the sample(s).

26. What does the abbreviation UCL stand for?
Hold all input variables constant except one. Observe the response as you vary the single input.
Upper control limit.
It's good -- but it's still out of control!
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

27. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Attribute.
Upper control limit.

28. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
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
The House of Quality.
To monitor a process when measurement by attribute is used.

29. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
100%
Attribute
10 if Almost impossible to detect

30. FMEA
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Prevention - appraisal - internal failure - external failure.
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

31. Name the structure associated with Quality Function Deployment.
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
=sqrt(Σ(x-x-bar)^2)/(n-1))
Attribute
The House of Quality.

32. What is a Pareto chart?
A descending order-sorted bar chart with a cumulative percentage line.
A tool that shows the physical flows through a space.
Rapid improvement process.
Attribute.

33. What is a CAVE man?
Mean time to replacement.
The House of Quality.
The Japanese national quality award.
Someone who is consistently against virtually everything.

34. Defect location check sheets
Blame.
Fractional factorial designs (orthogonal arrays)
Controlling quality at the source.
Actual drawings - layouts - maps - etc which show where a defect occurs

35. Define aesthetic quality.
Pleasing to the senses.
99.73%
Scrap - rework - retest - downtime - yield losses - disposition costs.
The Japanese national quality award.

36. Risk Priority Number RPN
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Method developed by Ishikawa to graphically display the causes of any given problem
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
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

37. Define yield.
Upper control limit.
Hold all input variables constant except one. Observe the response as you vary the single input.
The ratio of outputs to inputs; 1-scrap.
Lower control limit.

38. Complete this quality phrase: 'Fix the process - not the _____.'
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
No -- only if the process is also capable.
Blame.
A tool that shows the physical flows through a space.

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

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40. Non-random patterns (Run Charts)
Shifts - Trends - Repeating patterns - Correlation with known events
A tool that shows the physical flows through a space.
Attribute.
No -- if it is not the same - it can only be worse!

41. One factor at a time (OFAT)
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
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).
Fitness for use.
Observed variation in response is caused by the input

42. What does DMAIC stand for?
Define - measure - analyze - improve - control.
Mistake-proofing.
Controlling quality at the source.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

43. What is a histogram?
Lower control limit.
A tool that shows performance along key dimensions all at once.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
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

44. If you have calculated a Cpk - should you also calculate a Cp?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
A diagram that shows the relationships between activities in a project network.
Fewer good units to sell - increased variable cost/unit.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

45. Your production process meets customer specifications. Is your process in control?
Not necessarily.
The ratio of outputs to inputs; 1-scrap.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Lower control limit.

46. Test for constant variance
It's good -- but it's still out of control!
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Because the mean and standard deviation are independent of each other.
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.

47. What percentage of a normal distribution lies above the mean?
Sort - Set in Order - Shine - Standardize - Sustain
A diagram that shows the relationships between activities in a project network.
50%
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

48. Uses of regression - Control
To obtain a certain desirable outcome from the process
The degree to which a product meets pre-established standards.
The secondary characteristics of a product; "bells and whistles."
Can't tell without a Range chart.

49. List two appraisal costs.
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.
Someone who is consistently against virtually everything.
95%

50. In the Service Quality Gap Model - what is Gap 1?
They move closer to the center line.
The gap between what management thinks customers want and what customers really want.
Attribute.
Prevention - appraisal - internal failure - external failure.