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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 a Gage R&R?
Mean time to replacement.
Represents the behavior of a 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).
Lean is waste reduction - Six Sigma is variation reduction.

2. What are the three main categories of assignable cause?
False - because each machine will have different natural tolerances.
Workers - machines - materials.
95%
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

3. Detection Criteria Ranking
Look for the assignable cause of non-random variation.
Mean time to replacement.
Lower control limit.
10 if Almost impossible to detect

4. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
The gap between what management thinks customers want and the process specifications.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Lower skill requirements - faster - less chance for error.
To manage the Six Sigma project.

5. One factor at a time (OFAT)
Observed variation in response is caused by the input
Define - measure - analyze - improve - control.
The gap between what management thinks customers want and the process specifications.
Mean time to replacement.

6. What do you do when a process is out of control?
Stratify a particular defect type according to logical criteria
Central Limit Theorem
Walter A. Shewhart
Look for the assignable cause of non-random variation.

7. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Outside.
100%
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Pleasing to the senses.

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

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9. What is the role of a master black belt?
F_alpha - df(tr) - df (error)
To mentor/coach (and sometimes train) black belts.
To monitor a process when measurement by variables is used.
= 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

10. What is Type 1 Error?
Financial - customer - internal process - innovation and learning.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Concluding there has been an effect/change when there has not.

11. When is Cpk used?
Waste.
Shows the temporal flow of activities in a project network.
To do a capability study for a non-centered process.
Fewer good units to sell - increased variable cost/unit.

12. F value
Hold all input variables constant except one. Observe the response as you vary the single input.
False - because each machine will have different natural tolerances.
Mistake-proofing.
F_alpha - df(tr) - df (error)

13. In the Service Quality Gap Model - what is Gap 5?
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 gap between what customers expect and the service they receive.
No -- if it is not the same - it can only be worse!
To be a member of a Six Sigma project team.

14. In the Service Quality Gap Model - what is Gap 3?
95%
The gap between specifications and how service is performed.
The Japanese national quality award.
Deming.

15. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Causes that lead to a particular effect.
95%
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).
The ability of a process to consistently meet customer specifications.

16. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Attribute
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Large enough to find two of the attribute - on average.
= yij - y(bar)i --> value minus sum of that treatment (of row)

17. Advantages of DOE
Is the way in which the failure is manifested.
A tool that shows where there is waste in a process.
It's good -- but it's still out of control!
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

18. If a Cp shows that a process is not capable - should you calculate Cpk?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
No -- if it is not the same - it can only be worse!
Workers - machines - materials.
Is what induces the failure

19. How does Juran define quality?
Waste.
Fitness for use.
A scatterplot.
Used to create frequency distribution tally sheets

20. Cause and Effect Diagrams
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
Method developed by Ishikawa to graphically display the causes of any given problem
Outside.

21. What is written on the "spines" of a fishbone diagram?
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
Causes that lead to a particular effect.
The gap between what management thinks customers want and what customers really want.
The manager in charge of a process being improved in a Six Sigma project.

22. Effect ranking (Severity of the Defect)
p-bar - the long-run percent defective.
Fitness for use.
100%
10 for Hazardous without warning 1 for none

23. To what does the Six in Six Sigma relate?
The target number of standard deviations from the mean for specifications.
It's good -- but it's still out of control!
X-bar-bar
50%

24. Affinity Diagrams
Blame.
Organize ideas into meaningful categories by recognizing their underlying similarity
Is the way in which the failure is manifested.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

25. Failure Mode
Large enough to find two of the attribute - on average.
Scrap - rework - retest - downtime - yield losses - disposition costs.
The secondary characteristics of a product; "bells and whistles."
Is the way in which the failure is manifested.

26. If a three-stage process has 90% yields at each stage - what is the overall yield?
What the value of the dependent variable is when the independent variable is zero.
Large enough to find two of the attribute - on average.
Assigns scores to weighted criteria for each project under consideration.
0.9^3 or 72.9%

27. List two components of external failure.
Prevention - appraisal - internal failure - external failure.
The gap between what customers expect and the service they receive.
68%
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

28. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
The House of Quality.
No -- the variation also has to be random and "expected."
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
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

29. 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 do a capability study for a non-centered process.
A diagram that shows the relationships between activities in a project network.
To be a member of a Six Sigma project team.

30. Risk Priority Number RPN
Organize ideas into meaningful categories by recognizing their underlying similarity
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
A tool that shows the physical flows through a space.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

31. The Test Statistic (TS)
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).
A random variable that summarizes the information from the sample(s).
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The degree to which a product meets pre-established standards.

32. What size should samples be for attribute SPC?
Large enough to find two of the attribute - on average.
100%
0.9^3 or 72.9%
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

33. What is the role of a black belt?
The US national quality award.
Define - measure - analyze - improve - control.
Upper control limit.
To manage the Six Sigma project.

34. What type of risk is associated with Type 1 Error?
To be a member of a Six Sigma project team.
The gap between what management thinks customers want and the process specifications.
Controlling quality at the source.
Producer risk.

35. Statistical Hypothesis
Different types of defects are listed (used for Pareto chart)
Fishbone - cause-and-effect diagram.
An assertion or conjecture concerning one or more populations
=sqrt(Σ(x-x-bar)^2)/(n-1))

36. If you have calculated a Cpk - should you also calculate a Cp?
Consumer risk.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
100%
Lean is waste reduction - Six Sigma is variation reduction.

37. You have been plotting sample means on an x-bar chart and all points indicate normal - expected variation. Is the process in control?

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38. What is DMADV?
The Japanese national quality award.
Define - measure - analyze - design - verify.
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
Linearity - normality - homoscedasticity - independence.

39. Design of Experiments (DOE) approach
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
To be a member of a Six Sigma project team.
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:

40. What is the center line of an X-bar chart?
X-bar-bar
No -- if it is not the same - it can only be worse!
The primary operating characteristics of a product.
Can't tell without a Range chart.

41. Daniel Test
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
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:
X-bar-bar
99.73%

42. What graphical tool is used to show the relationship between two numerical variables?
0.9^3 or 72.9%
Financial - customer - internal process - innovation and learning.
A scatterplot.
=sqrt((p*(1-p)/n)

43. What are the Five Dimensions of Service Quality?
5%
Before production starts
= 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
Reliability - Assurance - Responsiveness - Tangibles - Empathy

44. Define serviceability.
Speed - courtesy - competence - and ease of repair.
Defects Per Million Opportunities
Deming.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

45. List Garvin's eight dimensions of product quality.
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:
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Attribute
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

46. Define takt time.
The cycle time required to meet demand.
X-bar-bar
Lower control limit.
Define - measure - analyze - design - verify.

47. Manual Test for Nomality
Define - measure - analyze - design - verify.
0.9^3 or 72.9%
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
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

48. List two components of internal failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
A time series plot.
Before production starts
10 if Almost impossible to detect

49. Process occurance ranking
99.73%
Lower skill requirements - faster - less chance for error.
Stratify a particular defect type according to logical criteria
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

50. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Sampling for SPC is done real time.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Conformance to specifications.
Sort - Set in Order - Shine - Standardize - Sustain