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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. Residual
Speed - courtesy - competence - and ease of repair.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Hold all input variables constant except one. Observe the response as you vary the single input.

2. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Lean (or JIT).
Is the way in which the failure is manifested.
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.
Sampling for SPC is done real time.

3. If you can only collect categorical data - what type of SPC charting can you do?
Attribute.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Conformance to specifications.
X-bar-bar

4. What is a Gage R&R?
To do a capability study for a non-centered 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).
Large enough to find two of the attribute - on average.
Outside.

5. Does it ever make sense to accept a job when a process is incapable?
3.4 (assuming 1.5 sigma shift in the mean)
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Lean (or JIT).
The secondary characteristics of a product; "bells and whistles."

6. Cause and Effect Diagrams
The ability of a process to consistently meet customer specifications.
Method developed by Ishikawa to graphically display the causes of any given problem
Fitness for use.
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

7. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
68%
0.9^3 or 72.9%
They move closer to the center line.
Attribute

8. What is a run chart?
Prevention - appraisal - internal failure - external failure.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Fewer good units to sell - increased variable cost/unit.
A time series plot.

9. What is written on the "spines" of a fishbone diagram?
95%
Sampling for SPC is done real time.
To do a capability study for a non-centered process.
Causes that lead to a particular effect.

10. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
The gap between what management thinks customers want and what customers really want.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Initiated before or at design concept finalization

11. What quality guru emphasizes management as a system?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Deming.
Large enough to find two of the attribute - on average.

12. Taguchi's experimental designs are of this type.
It's good -- but it's still out of control!
A tool that shows performance along key dimensions all at once.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Fractional factorial designs (orthogonal arrays)

13. Test for Independence
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
Upper control limit.
Defects Per Million Opportunities
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

14. Regression Analysis
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!
= yij - y(bar)i --> value minus sum of that treatment (of row)
Sampling for SPC is done real time.

15. What is a network diagram?
Supplier - input - process - output - customer.
The gap between what management thinks customers want and what customers really want.
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.
A diagram that shows the relationships between activities in a project network.

16. List two components of external failure.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Method developed by Ishikawa to graphically display the causes of any given problem
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Taguchi

17. FMEA
X-bar-bar
Assigns scores to weighted criteria for each project under consideration.
The manager in charge of a process being improved in a Six Sigma project.
It looks to minimize the probability of a failure - or to minimize its effects

18. DFMEA
Upper control limit.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Initiated before or at design concept finalization
10 for Hazardous without warning 1 for none

19. What does SIPOC stand for?
Supplier - input - process - output - customer.
Sampling for SPC is done real time.
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
Used to create frequency distribution tally sheets

20. What type of risk is associated with Type II Error?
=sqrt(Σ(x-x-bar)^2)/(n-1))
No -- only if the process is also capable.
The US national quality award.
Consumer risk.

21. What do you do when a process is out of control?
The gap between what management thinks customers want and what customers really want.
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).
No -- the variation also has to be random and "expected."
Look for the assignable cause of non-random variation.

22. What percentage of a normal distribution lies above the mean?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
The gap between what management thinks customers want and what customers really want.
The primary operating characteristics of a product.
50%

23. FMEA
A time series plot.
p-bar - the long-run percent defective.
Lean (or JIT).
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

24. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Shows the temporal flow of activities in a project network.
95%
Lean (or JIT).
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).

25. What quality tool formally incorporates the voice of the customer?
QFD
To manage the Six Sigma project.
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
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

26. What is the center line of a p-chart?
Central Limit Theorem
Look for the assignable cause of non-random variation.
The Japanese national quality award.
p-bar - the long-run percent defective.

27. In the Service Quality Gap Model - what is Gap 2?
Controlling quality at the source.
The gap between what management thinks customers want and the process specifications.
The manager in charge of a process being improved in a Six Sigma project.
0.9^3 or 72.9%

28. In a regression - what does R-square tell you?
Causes that lead to a particular effect.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Mistake-proofing.
Sampling for SPC is done real time.

29. Defect location check sheets
Actual drawings - layouts - maps - etc which show where a defect occurs
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Sampling for SPC is done real time.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

30. Define takt time.
The cycle time required to meet demand.
Shows the temporal flow of activities in a project network.
Sort - Set in Order - Shine - Standardize - Sustain
99.73%

31. Why do you need two control charts for variables SPC?
The Japanese national quality award.
Is what induces the failure
What the value of the dependent variable is when the independent variable is zero.
Because the mean and standard deviation are independent of each other.

32. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
The manager in charge of a process being improved in a Six Sigma project.
5%
To mentor/coach (and sometimes train) black belts.
Variable.

33. Simple Regression Analysis (one factor regression model)
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Technical quality is the "what" of the service; functional quality is the "how."
Rapid improvement process.
= 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

34. Explain the difference between technical and functional service quality.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Look for the assignable cause of non-random variation.
Technical quality is the "what" of the service; functional quality is the "how."
F_alpha - df(tr) - df (error)

35. What is a CAVE man?
Someone who is consistently against virtually everything.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Sampling for SPC is done real time.

36. One factor at a time (OFAT)
Variable.
The gap between what management thinks customers want and what customers really want.
Hold all input variables constant except one. Observe the response as you vary the single input.
No -- if it is not the same - it can only be worse!

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. Detection Criteria Ranking
A tool that shows the physical flows through a space.
The US national quality award.
10 if Almost impossible to detect
Lean is waste reduction - Six Sigma is variation reduction.

39. Define durability.
The manager in charge of a process being improved in a Six Sigma project.
Mean time to replacement.
Look for the assignable cause of non-random variation.
Conformance to specifications.

40. PFMEA
Waste.
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
Before production starts
Someone who is consistently against virtually everything.

41. Define conformance quality.
The degree to which a product meets pre-established standards.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Concluding there has not been an effect/change when there has.
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

42. Test for constant variance
The number of standard deviations some value is from the mean.
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.
Is the consequence of the failure.
To do a capability study for a non-centered process.

43. When yields decrease - what are the two effects on contribution?
Fewer good units to sell - increased variable cost/unit.
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:
Attribute.
Attribute

44. 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.
Lower skill requirements - faster - less chance for error.
The gap between what customers expect and the service they receive.
Look for the assignable cause of non-random variation.

45. What is a Gantt chart?
Speed - courtesy - competence - and ease of repair.
Shows the temporal flow of activities in a project network.
Supplier - input - process - output - customer.
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

46. Uses of regression - Control
To obtain a certain desirable outcome from the process
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
Critical to quality.
50%

47. What is an affinity diagram?
The gap between what management thinks customers want and the process specifications.
A brainstorming tool that shows the connections between ideas.
Rapid improvement process.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

48. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
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:
0.9^3 or 72.9%
What the value of the dependent variable is when the independent variable is zero.
No -- the variation also has to be random and "expected."

49. 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.
The target number of standard deviations from the mean for specifications.
Upper control limit.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

50. In the Service Quality Gap Model - what is Gap 3?
Central Limit Theorem
Outside.
The gap between specifications and how service is performed.
=sqrt((p*(1-p)/n)