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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 the role of a black belt?
To obtain a certain desirable outcome from the process
To manage the Six Sigma project.
Technical quality is the "what" of the service; functional quality is the "how."
The target number of standard deviations from the mean for specifications.

2. A process is operating "in control." Does this mean the customer's requirements are met?
No -- only if the process is also capable.
No -- the variation also has to be random and "expected."
QFD
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

3. What is Little's Law?
Inventory = throughput x flow time.
Blame.
Large enough to find two of the attribute - on average.
The secondary characteristics of a product; "bells and whistles."

4. What is the 5S model?
Kaoru Ishikawa.
= yij - y(bar)i --> value minus sum of that treatment (of row)
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Observed variation in response is caused by the input

5. What does the abbreviation UCL stand for?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Reliability - Assurance - Responsiveness - Tangibles - Empathy
The US national quality award.
Upper control limit.

6. What is the difference between Lean and Six Sigma?
Lean is waste reduction - Six Sigma is variation reduction.
= 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
Observed variation in response is caused by the input
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

7. DOE
The primary operating characteristics of a product.
= 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
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

8. What is FMEA?
Lower control limit.
=sqrt((p*(1-p)/n)
Hold all input variables constant except one. Observe the response as you vary the single input.
Failure Modes and Effects Analysis

9. Manual Test for Nomality
Outside.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
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
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

10. 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.
To monitor a process when measurement by variables is used.
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).
A random variable that summarizes the information from the sample(s).

11. Define serviceability.
Define - measure - analyze - design - verify.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Speed - courtesy - competence - and ease of repair.
10 if Almost impossible to detect

12. To what does the Six in Six Sigma relate?
Initiated before or at design concept finalization
A tool that shows the physical flows through a space.
The target number of standard deviations from the mean for specifications.
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

13. Define aesthetic quality.
Pleasing to the senses.
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 House of Quality.
Is what induces the failure

14. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Walter A. Shewhart
Lean is waste reduction - Six Sigma is variation reduction.
5%
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

15. What percentage of a normal distribution lies above the mean?
50%
68%
Is the consequence of the failure.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

16. What is muda
Waste.
The primary operating characteristics of a product.
Upper control limit.
Sampling for SPC is done real time.

17. Test for constant variance
It looks to minimize the probability of a failure - or to minimize its effects
F_alpha - df(tr) - df (error)
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.
To obtain a certain desirable outcome from the process

18. Pareto Analysis
The degree to which a product meets pre-established standards.
Lower skill requirements - faster - less chance for error.
The House of Quality.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

19. In a regression - what does the standard error of the estimate tell you?
Concluding there has not been an effect/change when there has.
Lean is waste reduction - Six Sigma is variation reduction.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Hold all input variables constant except one. Observe the response as you vary the single input.

20. Complete this quality phrase: 'Fix the process - not the _____.'
Blame.
Waste.
Is what induces the failure
The gap between what is promised and what is delivered.

21. With Six Sigma capability - how many defects per million opportunities would you see?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
3.4 (assuming 1.5 sigma shift in the mean)
Walter A. Shewhart
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

22. In a regression - what does R-square tell you?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
They move closer to the center line.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

23. Define performance quality.
The primary operating characteristics of a product.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Hold all input variables constant except one. Observe the response as you vary the single input.
Is the way in which the failure is manifested.

24. ANOVA

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25. Affinity Diagrams
Taguchi
Organize ideas into meaningful categories by recognizing their underlying similarity
Upper control limit.
The House of Quality.

26. Definition of Interaction
To obtain a certain desirable outcome from the process
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Can't tell without a Range chart.
To monitor a process when measurement by attribute is used.

27. What is a Gage R&R?
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).
The US national quality award.
The number of standard deviations some value is from the mean.
Initiated before or at design concept finalization

28. DFMEA
Fractional factorial designs (orthogonal arrays)
Mean time to replacement.
Initiated before or at design concept finalization
It looks to minimize the probability of a failure - or to minimize its effects

29. Disadvantages of DOE

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30. What is the Baldrige Award?
Mistake-proofing.
The US national quality award.
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
Brand image.

31. What does DMAIC stand for?
Someone who is consistently against virtually everything.
Define - measure - analyze - improve - control.
Inventory = throughput x flow time.
68%

32. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
= 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
Lean (or JIT).
=sqrt(Σ(x-x-bar)^2)/(n-1))
To mentor/coach (and sometimes train) black belts.

33. What is process capability?
Scrap - rework - retest - downtime - yield losses - disposition costs.
The ability of a process to consistently meet customer specifications.
Prevention - appraisal - internal failure - external failure.
A time series plot.

34. When is Cpk 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
To do a capability study for a non-centered process.
The gap between what customers expect and the service they receive.
Fishbone - cause-and-effect diagram.

35. Non-random patterns (Run Charts)
Deming.
Not necessarily.
The degree to which a product meets pre-established standards.
Shifts - Trends - Repeating patterns - Correlation with known events

36. What does a project prioritization matrix do?
To do a capability study for a non-centered process.
Assigns scores to weighted criteria for each project under consideration.
Mean time to failure.
To monitor a process when measurement by variables is used.

37. What is the formula for standard deviation?
Define - measure - analyze - design - verify.
Shifts - Trends - Repeating patterns - Correlation with known events
99.73%
=sqrt(Σ(x-x-bar)^2)/(n-1))

38. What is written on the "spines" of a fishbone diagram?
Causes that lead to a particular effect.
= 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
Observed variation in response is caused by the input
Used to create frequency distribution tally sheets

39. 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.
The number of standard deviations some value is from the mean.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
F_alpha - df(tr) - df (error)

40. What is DMADV?
Prevention and appraisal costs are balanced against internal and external failure.
Deming.
Define - measure - analyze - design - verify.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

41. What do you do when a process is out of control?
Look for the assignable cause of non-random variation.
Organize ideas into meaningful categories by recognizing their underlying similarity
Mean time to replacement.
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

42. There are two milling machines in the shop. Data has been collected on one to compute control limits for both. This is acceptable SPC practice - true or false and why?
Concluding there has not been an effect/change when there has.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Variable.
False - because each machine will have different natural tolerances.

43. Simple Regression Analysis (one factor regression model)
Linearity - normality - homoscedasticity - independence.
= 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
Not necessarily.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

44. What is a Pareto chart?
Shifts - Trends - Repeating patterns - Correlation with known events
Linearity - normality - homoscedasticity - independence.
A descending order-sorted bar chart with a cumulative percentage line.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

45. How does Juran define quality?
Mean time to replacement.
To do a capability study for a non-centered process.
Fitness for use.
Rapid improvement process.

46. Define conformance quality.
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.
Rapid improvement process.
The degree to which a product meets pre-established standards.

47. What size should samples be for attribute SPC?
Is the consequence of the failure.
A tool that shows the physical flows through a space.
Large enough to find two of the attribute - on average.
To do a capability study for a non-centered process.

48. 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.
Define - measure - analyze - improve - control.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Producer risk.

49. Detection Criteria Ranking
Workers - machines - materials.
10 if Almost impossible to detect
Conformance to specifications.
Blame.

50. Who developed the fishbone diagram?
Initiated before or at design concept finalization
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Studying firms with the best performance in a particular area.
Kaoru Ishikawa.