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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. One factor at a time (OFAT)
Conformance to specifications.
To be a member of a Six Sigma project team.
Hold all input variables constant except one. Observe the response as you vary the single input.
Prevention - appraisal - internal failure - external failure.

2. Residual(eij)
Is the way in which the failure is manifested.
Failure Modes and Effects Analysis
A random variable that summarizes the information from the sample(s).
= yij - y(bar)i --> value minus sum of that treatment (of row)

3. What is a histogram?
Represents the behavior of a process
Actual drawings - layouts - maps - etc which show where a defect occurs
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
95%

4. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
A tool that shows performance along key dimensions all at once.
95%
Conformance to specifications.
No -- if it is not the same - it can only be worse!

5. What is poka yoke?
A tool that shows where there is waste in a process.
The cycle time required to meet demand.
Mistake-proofing.
Inventory = throughput x flow time.

6. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
Lean is waste reduction - Six Sigma is variation reduction.
Fractional factorial designs (orthogonal arrays)
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.
100%

7. Uses of regression
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Mean time to replacement.
3.4 (assuming 1.5 sigma shift in the mean)
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

8. Complete this quality phrase: 'Fix the process - not the _____.'
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).
Assigns scores to weighted criteria for each project under consideration.
Blame.
100%

9. DOE
50%
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
To be a member of a Six Sigma project team.

10. Failure effect
The US national quality award.
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
Is the consequence of the failure.
The ratio of outputs to inputs; 1-scrap.

11. Stratified defect check sheets
Through producer/consumer negotiation.
The target number of standard deviations from the mean for specifications.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Stratify a particular defect type according to logical criteria

12. What is FMEA?
Critical to quality.
95%
Failure Modes and Effects Analysis
Attribute

13. Defect location check sheets
Actual drawings - layouts - maps - etc which show where a defect occurs
Variable.
Linearity - normality - homoscedasticity - independence.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

14. Defect check sheets
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The gap between what management thinks customers want and the process specifications.
The target number of standard deviations from the mean for specifications.
Different types of defects are listed (used for Pareto chart)

15. What is process capability?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Causes that lead to a particular effect.
The ability of a process to consistently meet customer specifications.
A time series plot.

16. Define benchmarking.
Financial - customer - internal process - innovation and learning.
They move closer to the center line.
Studying firms with the best performance in a particular area.
A time series plot.

17. Regression Analysis
Producer risk.
Used to create frequency distribution tally sheets
Through producer/consumer negotiation.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

18. Process check sheets
Sampling for SPC is done real time.
Used to create frequency distribution tally sheets
Rapid improvement 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:

19. What is a CAVE man?
QFD
Speed - courtesy - competence - and ease of repair.
Someone who is consistently against virtually everything.
Walter A. Shewhart

20. What is an affinity diagram?
A tool that shows where there is waste in a process.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The cycle time required to meet demand.
A brainstorming tool that shows the connections between ideas.

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

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22. A process is operating "in control." Does this mean the customer's requirements are met?
No -- only if the process is also capable.
A scatterplot.
What the value of the dependent variable is when the independent variable is zero.
Prevention and appraisal costs are balanced against internal and external failure.

23. Your production process meets customer specifications. Is your process in control?
Not necessarily.
It looks to minimize the probability of a failure - or to minimize its effects
Hold all input variables constant except one. Observe the response as you vary the single input.
Lower control limit.

24. What is Little's Law?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Financial - customer - internal process - innovation and learning.
Inventory = throughput x flow time.
99.73%

25. What is the 5S model?
A tool that shows the physical flows through a space.
F_alpha - df(tr) - df (error)
The manager in charge of a process being improved in a Six Sigma project.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

26. Define takt time.
The cycle time required to meet demand.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
The gap between specifications and how service is performed.
Initiated before or at design concept finalization

27. What quality tool formally incorporates the voice of the customer?
The gap between what management thinks customers want and what customers really want.
Different types of defects are listed (used for Pareto chart)
5%
QFD

28. In the Service Quality Gap Model - what is Gap 1?
The gap between what management thinks customers want and what customers really want.
The target number of standard deviations from the mean for specifications.
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
Lean (or JIT).

29. What are the four perspectives of the Balanced Scorecard?
Financial - customer - internal process - innovation and learning.
No -- the variation also has to be random and "expected."
Large enough to find two of the attribute - on average.
Technical quality is the "what" of the service; functional quality is the "how."

30. What is a network diagram?
A diagram that shows the relationships between activities in a project network.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
A scatterplot.

31. If a three-stage process has 90% yields at each stage - what is the overall yield?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
No -- if it is not the same - it can only be worse!
0.9^3 or 72.9%
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

32. Which quality guru developed the concept of loss to society?
3.4 (assuming 1.5 sigma shift in the mean)
Taguchi
Lower skill requirements - faster - less chance for error.
Fractional factorial designs (orthogonal arrays)

33. Detection Criteria Ranking
10 if Almost impossible to detect
A tool that shows the physical flows through a space.
Controlling quality at the source.
Blame.

34. Process occurance ranking
Attribute
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The secondary characteristics of a product; "bells and whistles."
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

35. What do you do when a process is out of control?
The US national quality award.
The target number of standard deviations from the mean for specifications.
Look for the assignable cause of non-random variation.
Represents the behavior of a process

36. 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).
Sort - Set in Order - Shine - Standardize - Sustain
Because the mean and standard deviation are independent of each other.
An assertion or conjecture concerning one or more populations

37. Pareto Analysis
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
A scatterplot.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Supplier - input - process - output - customer.

38. What is the role of a master black belt?
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
To mentor/coach (and sometimes train) black belts.
Financial - customer - internal process - innovation and learning.
Taguchi

39. What is the Baldrige Award?
Outside.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
The US national quality award.
The cycle time required to meet demand.

40. Define perceived quality (Garvin's framework).
Fitness for use.
Brand image.
Mean time to replacement.
Mistake-proofing.

41. What is a run chart?
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Lower skill requirements - faster - less chance for error.
A time series plot.
Stratify a particular defect type according to logical criteria

42. What is the formula for standard deviation?
The Japanese national quality award.
=sqrt(Σ(x-x-bar)^2)/(n-1))
The cycle time required to meet demand.
It's good -- but it's still out of control!

43. What is CTQ?
Lower skill requirements - faster - less chance for error.
A scatterplot.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Critical to quality.

44. What are the three main categories of assignable cause?
Lower control limit.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Workers - machines - materials.

45. What does a project prioritization matrix do?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
To monitor a process when measurement by attribute 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
Assigns scores to weighted criteria for each project under consideration.

46. Creating a Run Chart
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Controlling quality at the source.
Blame.
Technical quality is the "what" of the service; functional quality is the "how."

47. What is a dashboard?
Conformance to specifications.
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
A tool that shows performance along key dimensions all at once.

48. In a regression - what does the standard error of the estimate tell you?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
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.
The Japanese national quality award.

49. What does DMAIC stand for?
False - because each machine will have different natural tolerances.
To obtain a certain desirable outcome from the process
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Define - measure - analyze - improve - control.

50. Definition of Interaction
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Prevention - appraisal - internal failure - external failure.
Can't tell without a Range chart.