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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 the center line of an X-bar chart?
F_alpha - df(tr) - df (error)
X-bar-bar
Shows the temporal flow of activities in a project network.
Through producer/consumer negotiation.

2. What is Type II Error?
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
Concluding there has not been an effect/change when there has.
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 gap between specifications and how service is performed.

3. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Outside.
Through producer/consumer negotiation.
= yij - y(bar)i --> value minus sum of that treatment (of row)
No -- the variation also has to be random and "expected."

4. Pareto Analysis
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Fishbone - cause-and-effect diagram.
Lean (or JIT).
Prevention - appraisal - internal failure - external failure.

5. Non-random patterns (Run Charts)
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Shifts - Trends - Repeating patterns - Correlation with known events
What the value of the dependent variable is when the independent variable is zero.
To do a capability study for a non-centered process.

6. What does the abbreviation LCL stand for?
Lower control limit.
Concluding there has not been an effect/change when there has.
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:
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

7. What is written on the "spines" of a fishbone diagram?
Causes that lead to a particular effect.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The primary operating characteristics of a product.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

8. Test for constant variance
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
99.73%
Method developed by Ishikawa to graphically display the causes of any given problem
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.

9. What is poka yoke?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Shows the temporal flow of activities in a project network.
Failure Modes and Effects Analysis
Mistake-proofing.

10. What is a dashboard?
Central Limit Theorem
Fitness for use.
To mentor/coach (and sometimes train) black belts.
A tool that shows performance along key dimensions all at once.

11. With Six Sigma capability - how many defects per million opportunities would you see?
3.4 (assuming 1.5 sigma shift in the mean)
Pleasing to the senses.
99.73%
Upper control limit.

12. Defect location check sheets
Actual drawings - layouts - maps - etc which show where a defect occurs
The cycle time required to meet demand.
Someone who is consistently against virtually everything.
Controlling quality at the source.

13. Statistical Hypothesis
An assertion or conjecture concerning one or more populations
A tool that shows performance along key dimensions all at once.
Prevention and appraisal costs are balanced against internal and external failure.
The Japanese national quality award.

14. A process is operating "in control." Does this mean the customer's requirements are met?
Outside.
A brainstorming tool that shows the connections between ideas.
No -- only if the process is also capable.
Prevention - appraisal - internal failure - external failure.

15. What is Little's Law?
Inventory = throughput x flow time.
QFD
A random variable that summarizes the information from the sample(s).
=sqrt((p*(1-p)/n)

16. Histogram by Hand
Financial - customer - internal process - innovation and learning.
The gap between what management thinks customers want and what customers really want.
100%
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

17. One factor at a time (OFAT)
Financial - customer - internal process - innovation and learning.
Hold all input variables constant except one. Observe the response as you vary the single input.
95%
To do a capability study for a non-centered process.

18. TWO-DIMENTIONAL SCATTER PLOT
Concluding there has not been an effect/change when there has.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
A descending order-sorted bar chart with a cumulative percentage line.
Producer risk.

19. For what is a p-chart used?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
To monitor a process when measurement by attribute is used.
Critical to quality.
Sort - Set in Order - Shine - Standardize - Sustain

20. If you have calculated a Cpk - should you also calculate a Cp?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Walter A. Shewhart
X-bar-bar
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).

21. Define durability.
Mean time to replacement.
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
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The gap between what customers expect and the service they receive.

22. Regression Analysis
Taguchi
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
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)

23. What quality tool formally incorporates the voice of the customer?
Mistake-proofing.
QFD
The gap between what customers expect and the service they receive.
The primary operating characteristics of a product.

24. What is DPMO?
Shows the temporal flow of activities in a project network.
Defects Per Million Opportunities
Is what induces the failure
Blame.

25. 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.
To monitor a process when measurement by variables is used.
Producer risk.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

26. In a Z table - what is Z?
The number of standard deviations some value is from the mean.
0.9^3 or 72.9%
False - because each machine will have different natural tolerances.
Upper control limit.

27. Who first studied randomness in industrial processes
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
Walter A. Shewhart
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The primary operating characteristics of a product.

28. FMEA
= 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
It looks to minimize the probability of a failure - or to minimize its effects
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
Defects Per Million Opportunities

29. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Kaoru Ishikawa.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
To do a capability study for a non-centered process.
Lean (or JIT).

30. What is Kaizen?
Brand image.
Concluding there has been an effect/change when there has not.
Critical to quality.
Rapid improvement process.

31. Simple Regression Analysis (one factor regression model)
= 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
Financial - customer - internal process - innovation and learning.
The target number of standard deviations from the mean for specifications.
To do a capability study for a non-centered process.

32. In the Service Quality Gap Model - what is Gap 5?
Mean time to failure.
The gap between what customers expect and the service they receive.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
If the Response vs. Levels graph if the response lines are not parallel (crossing)

33. Design of Experiments (DOE) approach
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Is the way in which the failure is manifested.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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.

34. DFMEA
Financial - customer - internal process - innovation and learning.
Initiated before or at design concept finalization
Lower skill requirements - faster - less chance for error.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

35. In a regression - what does the standard error of the estimate tell you?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Lower control limit.
= 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
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

36. What type of risk is associated with Type II Error?
Consumer risk.
To manage the Six Sigma project.
Financial - customer - internal process - innovation and learning.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

37. List Garvin's eight dimensions of product quality.
10 for Hazardous without warning 1 for none
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Taguchi

38. In the Service Quality Gap Model - what is Gap 1?
The target number of standard deviations from the mean for specifications.
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 what customers really want.
Lower skill requirements - faster - less chance for error.

39. If a three-stage process has 90% yields at each stage - what is the overall yield?
0.9^3 or 72.9%
Financial - customer - internal process - innovation and learning.
The target number of standard deviations from the mean for specifications.
The primary operating characteristics of a product.

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

41. What is process capability?
Lower skill requirements - faster - less chance for error.
Fitness for use.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
The ability of a process to consistently meet customer specifications.

42. What is a CAVE man?
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
Organize ideas into meaningful categories by recognizing their underlying similarity
Someone who is consistently against virtually everything.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

43. What is the role of a black belt?
To manage the Six Sigma project.
Lean (or JIT).
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
They move closer to the center line.

44. What is the role of a green belt?
To be a member of a Six Sigma project team.
50%
Different types of defects are listed (used for Pareto chart)
The gap between what customers expect and the service they receive.

45. When yields decrease - what are the two effects on contribution?
Fewer good units to sell - increased variable cost/unit.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Variable.
Fitness for use.

46. What is the Deming Prize?
Mean time to failure.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
The Japanese national quality award.
= yij - y(bar)i --> value minus sum of that treatment (of row)

47. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Not necessarily.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Sampling for SPC is done real time.
Defects Per Million Opportunities

48. To what does the Six in Six Sigma relate?
Brand image.
Lean (or JIT).
Conformance to specifications.
The target number of standard deviations from the mean for specifications.

49. What are the four perspectives of the Balanced Scorecard?
Financial - customer - internal process - innovation and learning.
95%
Taguchi
Fishbone - cause-and-effect diagram.

50. Define conformance quality.
Not necessarily.
F_alpha - df(tr) - df (error)
X-bar-bar
The degree to which a product meets pre-established standards.