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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. In the Service Quality Gap Model - what is Gap 1?
Fishbone - cause-and-effect diagram.
The gap between what management thinks customers want and what customers really want.
A descending order-sorted bar chart with a cumulative percentage line.
Concluding there has not been an effect/change when there has.

2. Define benchmarking.
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
Studying firms with the best performance in a particular area.
They move closer to the center line.
It's good -- but it's still out of control!

3. How are LQL and AQL determined in an acceptance sampling plan?
The target number of standard deviations from the mean for specifications.
Technical quality is the "what" of the service; functional quality is the "how."
Through producer/consumer negotiation.
Used to create frequency distribution tally sheets

4. What is a run chart?
Fitness for use.
A tool that shows where there is waste in a process.
A time series plot.
Blame.

5. Affinity Diagrams
The gap between what customers expect and the service they receive.
Financial - customer - internal process - innovation and learning.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
The gap between what management thinks customers want and the process specifications.

6. What are the 5 Ss?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
The primary operating characteristics of a product.
Sort - Set in Order - Shine - Standardize - Sustain
Attribute.

7. What is Little's Law?
Scrap - rework - retest - downtime - yield losses - disposition costs.
Inventory = throughput x flow time.
Supplier - input - process - output - customer.
Initiated before or at design concept finalization

8. Who is a process owner?
Walter A. Shewhart
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The manager in charge of a process being improved in a Six Sigma project.
Initiated before or at design concept finalization

9. If you can only collect categorical data - what type of SPC charting can you do?
Attribute.
Define - measure - analyze - design - verify.
Mistake-proofing.
The target number of standard deviations from the mean for specifications.

10. Advantages of DOE
Pleasing to the senses.
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
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Look for the assignable cause of non-random variation.

11. What happens to control limits on an SPC chart when sample size is increased?
They move closer to the center line.
Define - measure - analyze - design - verify.
Producer risk.
Walter A. Shewhart

12. DFMEA
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Initiated before or at design concept finalization
Fractional factorial designs (orthogonal arrays)

13. What percentage of a normal distribution lies above the mean?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Fractional factorial designs (orthogonal arrays)
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
50%

14. Process check sheets
Used to create frequency distribution tally sheets
Is the consequence of the failure.
Taguchi
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

15. Test for Independence
Define - measure - analyze - design - verify.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
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
Pleasing to the senses.

16. What are the four regression assumptions?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Taguchi
To monitor a process when measurement by attribute is used.
Linearity - normality - homoscedasticity - independence.

17. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Upper control limit.
Shifts - Trends - Repeating patterns - Correlation with known events
Method developed by Ishikawa to graphically display the causes of any given problem
Lean (or JIT).

18. 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).
To obtain a certain desirable outcome from the process
The cycle time required to meet demand.
Defects Per Million Opportunities

19. 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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20. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
Waste.
To obtain a certain desirable outcome from the process
Speed - courtesy - competence - and ease of repair.

21. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
68%
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.
100%

22. What is the 5S model?
Sampling for SPC is done real time.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
5%

23. Uses of regression - Control
Someone who is consistently against virtually everything.
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
Brand image.

24. List Garvin's eight dimensions of product quality.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Hold all input variables constant except one. Observe the response as you vary the single input.
Taguchi
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. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Variable.
The manager in charge of a process being improved in a Six Sigma project.
No -- only if the process is also capable.

26. In Juran's Cost of Quality model - which categories of costs balance which other categories?
The degree to which a product meets pre-established standards.
Prevention and appraisal costs are balanced against internal and external failure.
A tool that shows the physical flows through a space.
Conformance to specifications.

27. What do you do when a process is out of control?
Mistake-proofing.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Look for the assignable cause of non-random variation.
The Japanese national quality award.

28. In the Service Quality Gap Model - what is Gap 3?
To manage the Six Sigma project.
The gap between specifications and how service is performed.
Deming.
Attribute.

29. What is FMEA?
To be a member of a Six Sigma project team.
QFD
Sampling for SPC is done real time.
Failure Modes and Effects Analysis

30. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Workers - machines - materials.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
50%
5%

31. What is a histogram?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Producer risk.
Supplier - input - process - output - customer.
To monitor a process when measurement by variables is used.

32. TWO-DIMENTIONAL SCATTER PLOT
Rapid improvement process.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Speed - courtesy - competence - and ease of repair.
Upper control limit.

33. When yields decrease - what are the two effects on contribution?
Fewer good units to sell - increased variable cost/unit.
Lean is waste reduction - Six Sigma is variation reduction.
The target number of standard deviations from the mean for specifications.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

34. What is a network diagram?
A diagram that shows the relationships between activities in a project network.
QFD
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 do a capability study for a non-centered process.

35. What is the formula for standard deviation?
Define - measure - analyze - design - verify.
= 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
=sqrt(Σ(x-x-bar)^2)/(n-1))
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

36. What are the four categories of costs in Juran's framework?
Organize ideas into meaningful categories by recognizing their underlying similarity
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Prevention - appraisal - internal failure - external failure.

37. If a three-stage process has 90% yields at each stage - what is the overall yield?
Fitness for use.
p-bar - the long-run percent defective.
0.9^3 or 72.9%
Sort - Set in Order - Shine - Standardize - Sustain

38. What is process capability?
Attribute.
The ability of a process to consistently meet customer specifications.
Shows the temporal flow of activities in a project network.
Can't tell without a Range chart.

39. What is the center line of a p-chart?
Conformance to specifications.
p-bar - the long-run percent defective.
Organize ideas into meaningful categories by recognizing their underlying similarity
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

40. Define durability.
To monitor a process when measurement by variables is used.
Mean time to failure.
68%
Mean time to replacement.

41. What is the formula for the standard deviation of a proportion?
To monitor a process when measurement by attribute is used.
=sqrt((p*(1-p)/n)
To do a capability study for a non-centered process.
Is the way in which the failure is manifested.

42. Residual
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
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
Variable.
Consumer risk.

43. What does DMAIC stand for?
Sampling for SPC is done real time.
Different types of defects are listed (used for Pareto chart)
Define - measure - analyze - improve - control.
Someone who is consistently against virtually everything.

44. Define features.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The secondary characteristics of a product; "bells and whistles."
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

45. What is a dashboard?
0.9^3 or 72.9%
Scrap - rework - retest - downtime - yield losses - disposition costs.
Critical to quality.
A tool that shows performance along key dimensions all at once.

46. Affinity Diagrams
Organize ideas into meaningful categories by recognizing their underlying similarity
Look for the assignable cause of non-random variation.
Initiated before or at design concept finalization
Mean time to failure.

47. With Six Sigma capability - how many defects per million opportunities would you see?
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Different types of defects are listed (used for Pareto chart)
3.4 (assuming 1.5 sigma shift in the mean)

48. Who developed the fishbone diagram?
Is what induces the failure
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Kaoru Ishikawa.
Waste.

49. Residual(eij)
= yij - y(bar)i --> value minus sum of that treatment (of row)
Critical to quality.
Consumer risk.
Lean is waste reduction - Six Sigma is variation reduction.

50. DOE
Technical quality is the "what" of the service; functional quality is the "how."
Define - measure - analyze - design - verify.
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).
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan