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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 graphical tool is used to show the relationship between two numerical variables?
Represents the behavior of a process
Taguchi
A scatterplot.
The Japanese national quality award.

2. What is the role of a master black belt?
Actual drawings - layouts - maps - etc which show where a defect occurs
To manage the Six Sigma project.
To mentor/coach (and sometimes train) black belts.
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. Which quality guru developed the concept of loss to society?
Concluding there has been an effect/change when there has not.
A scatterplot.
Taguchi
Actual drawings - layouts - maps - etc which show where a defect occurs

4. With Six Sigma capability - how many defects per million opportunities would you see?
Define - measure - analyze - design - verify.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
They move closer to the center line.
3.4 (assuming 1.5 sigma shift in the mean)

5. What is a histogram?
A tool that shows where there is waste in a process.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The degree to which a product meets pre-established standards.

6. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Lean (or JIT).
Fewer good units to sell - increased variable cost/unit.
Walter A. Shewhart
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

7. What is the difference between Lean and Six Sigma?
Fewer good units to sell - increased variable cost/unit.
Lean is waste reduction - Six Sigma is variation reduction.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Fishbone - cause-and-effect diagram.

8. PFMEA
Variable.
Before production starts
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
The US national quality award.

9. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Conformance to specifications.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
99.73%

10. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
To do a capability study for a non-centered process.
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.

11. What is Type 1 Error?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Concluding there has been an effect/change when there has not.
Lower skill requirements - faster - less chance for error.
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).

12. What is muda
10 if Almost impossible to detect
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Scrap - rework - retest - downtime - yield losses - disposition costs.
Waste.

13. Define perceived quality (Garvin's framework).
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Brand image.
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
Sort - Set in Order - Shine - Standardize - Sustain

14. What is Kaizen?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
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
Mean time to replacement.
Rapid improvement process.

15. 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.
Mean time to replacement.
Stratify a particular defect type according to logical criteria
X-bar-bar

16. Creating a Run Chart
The primary operating characteristics of a product.
Someone who is consistently against virtually everything.
Assigns scores to weighted criteria for each project under consideration.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

17. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
68%
Is the way in which the failure is manifested.
It looks to minimize the probability of a failure - or to minimize its effects
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

18. 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.
A diagram that shows the relationships between activities in a project network.
Organize ideas into meaningful categories by recognizing their underlying similarity
No -- only if the process is also capable.

19. What is a run chart?
99.73%
The gap between what management thinks customers want and what customers really want.
A time series plot.
Lean (or JIT).

20. Statistical Hypothesis
No -- only if the process is also capable.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
An assertion or conjecture concerning one or more populations
It looks to minimize the probability of a failure - or to minimize its effects

21. Test for Independence
A brainstorming tool that shows the connections between ideas.
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
Inventory = throughput x flow time.
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. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
Initiated before or at design concept finalization
To do a capability study for a non-centered process.
Through producer/consumer negotiation.

23. In the Service Quality Gap Model - what is Gap 1?
Look for the assignable cause of non-random variation.
The gap between what management thinks customers want and what customers really want.
Concluding there has not been an effect/change when there has.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

24. Non-random patterns (Run Charts)
Speed - courtesy - competence - and ease of repair.
Shifts - Trends - Repeating patterns - Correlation with known events
Variable.
A tool that shows performance along key dimensions all at once.

25. In the Service Quality Gap Model - what is Gap 3?
Represents the behavior of a process
Through producer/consumer negotiation.
The gap between specifications and how service is performed.
Stratify a particular defect type according to logical criteria

26. Process occurance ranking
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

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

28. What are the 5 Ss?
Sort - Set in Order - Shine - Standardize - Sustain
Fractional factorial designs (orthogonal arrays)
Scrap - rework - retest - downtime - yield losses - disposition costs.
Studying firms with the best performance in a particular area.

29. When yields decrease - what are the two effects on contribution?
Fewer good units to sell - increased variable cost/unit.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Technical quality is the "what" of the service; functional quality is the "how."

30. If you can only collect categorical data - what type of SPC charting can you do?
= 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
Waste.
Attribute.
Is what induces the failure

31. Histogram by Hand
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
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
A random variable that summarizes the information from the sample(s).
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

32. What type of risk is associated with Type II Error?
Blame.
Walter A. Shewhart
Before production starts
Consumer risk.

33. What is CTQ?
The secondary characteristics of a product; "bells and whistles."
10 for Hazardous without warning 1 for none
The cycle time required to meet demand.
Critical to quality.

34. Pareto Analysis
Because the mean and standard deviation are independent of each other.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Pleasing to the senses.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

35. If a three-stage process has 90% yields at each stage - what is the overall yield?
Mean time to failure.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
0.9^3 or 72.9%
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:

36. The Test Statistic (TS)
The gap between specifications and how service is performed.
0.9^3 or 72.9%
Method developed by Ishikawa to graphically display the causes of any given problem
A random variable that summarizes the information from the sample(s).

37. Simple Regression Analysis (one factor regression model)
Outside.
Is what induces the 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
Mistake-proofing.

38. What are the Five Dimensions of Service Quality?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
A brainstorming tool that shows the connections between ideas.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

39. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
A tool that shows where there is waste in a process.
99.73%
Attribute
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

40. What is a Gantt chart?
The primary operating characteristics of a product.
Shows the temporal flow of activities in a project network.
To do a capability study for a non-centered process.
Kaoru Ishikawa.

41. What is the center line of an X-bar chart?
Attribute.
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
Observed variation in response is caused by the input
X-bar-bar

42. What is Jidoka?
Controlling quality at the source.
Technical quality is the "what" of the service; functional quality is the "how."
A brainstorming tool that shows the connections between ideas.
68%

43. What is a Gage R&R?
Lower skill requirements - faster - less chance for error.
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
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).
Financial - customer - internal process - innovation and learning.

44. If you have calculated a Cpk - should you also calculate a Cp?
Supplier - input - process - output - customer.
Used to create frequency distribution tally sheets
A scatterplot.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

45. Affinity Diagrams
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
They move closer to the center line.
It's good -- but it's still out of control!
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

46. Regression Analysis
Observed variation in response is caused by the input
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
To obtain a certain desirable outcome from the process
Prevention and appraisal costs are balanced against internal and external failure.

47. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
To obtain a certain desirable outcome from the process
Lean is waste reduction - Six Sigma is variation reduction.
F_alpha - df(tr) - df (error)

48. For what is an x-bar chart used?
10 for Hazardous without warning 1 for none
No -- only if the process is also capable.
Variable.
To monitor a process when measurement by variables is used.

49. What is the Baldrige Award?
The US national quality award.
Upper control limit.
False - because each machine will have different natural tolerances.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

50. What is DPMO?
Defects Per Million Opportunities
Look for the assignable cause of non-random variation.
=sqrt((p*(1-p)/n)
The cycle time required to meet demand.