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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. Define aesthetic quality.
Taguchi
Observed variation in response is caused by the input
Pleasing to the senses.
They move closer to the center line.

2. What are the four categories of costs in Juran's framework?
Prevention - appraisal - internal failure - external failure.
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:
Assigns scores to weighted criteria for each project under consideration.
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

3. How are LQL and AQL determined in an acceptance sampling plan?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
The gap between specifications and how service is performed.
Through producer/consumer negotiation.
Brand image.

4. What are the four regression assumptions?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Linearity - normality - homoscedasticity - independence.
Shifts - Trends - Repeating patterns - Correlation with known events
Causes that lead to a particular effect.

5. FMEA
Speed - courtesy - competence - and ease of repair.
Sampling for SPC is done real time.
Fewer good units to sell - increased variable cost/unit.
It looks to minimize the probability of a failure - or to minimize its effects

6. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
To be a member of a Six Sigma project team.
5%
Mean time to replacement.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

7. Define performance quality.
The primary operating characteristics of a product.
Defects Per Million Opportunities
The gap between specifications and how service is performed.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

8. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Look for the assignable cause of non-random variation.
To monitor a process when measurement by attribute is used.
100%

9. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Sampling for SPC is done real time.
Shifts - Trends - Repeating patterns - Correlation with known events
=sqrt(Σ(x-x-bar)^2)/(n-1))
A tool that shows the physical flows through a space.

10. What is the 5S model?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The gap between what is promised and what is delivered.
Represents the behavior of a process
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

11. What happens to control limits on an SPC chart when sample size is increased?
They move closer to the center line.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
A scatterplot.
To monitor a process when measurement by variables is used.

12. What is the center line of an X-bar chart?
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).
X-bar-bar
Concluding there has been an effect/change when there has not.
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.

13. What is written on the "spines" of a fishbone diagram?
A diagram that shows the relationships between activities in a project network.
Supplier - input - process - output - customer.
Large enough to find two of the attribute - on average.
Causes that lead to a particular effect.

14. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
QFD
Define - measure - analyze - design - verify.
False - because each machine will have different natural tolerances.

15. Presence of interaction effect
Brand image.
Lean is waste reduction - Six Sigma is variation reduction.
Large enough to find two of the attribute - on average.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

16. What is the formula for standard deviation?
5%
=sqrt(Σ(x-x-bar)^2)/(n-1))
Causes that lead to a particular effect.
Concluding there has not been an effect/change when there has.

17. In the Service Quality Gap Model - what is Gap 3?
F_alpha - df(tr) - df (error)
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
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The gap between specifications and how service is performed.

18. Complete this quality phrase: 'Fix the process - not the _____.'
Assigns scores to weighted criteria for each project under consideration.
Blame.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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).

19. What is the center line of a p-chart?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Large enough to find two of the attribute - on average.
p-bar - the long-run percent defective.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

20. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Prevention - appraisal - internal failure - external failure.
The gap between what customers expect and the service they receive.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

21. Stratified defect check sheets
Consumer risk.
Attribute.
Stratify a particular defect type according to logical criteria
An assertion or conjecture concerning one or more populations

22. Affinity Diagrams
Is the way in which the failure is manifested.
Prevention - appraisal - internal failure - external failure.
Concluding there has been an effect/change when there has not.
Organize ideas into meaningful categories by recognizing their underlying similarity

23. Defect location check sheets
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Prevention - appraisal - internal failure - external failure.
Mean time to failure.
Actual drawings - layouts - maps - etc which show where a defect occurs

24. What is a spaghetti diagram?
False - because each machine will have different natural tolerances.
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 tool that shows the physical flows through a space.
Represents the behavior of a process

25. What quality guru emphasizes management as a system?
Pleasing to the senses.
F_alpha - df(tr) - df (error)
The gap between what management thinks customers want and the process specifications.
Deming.

26. Defect check sheets
Speed - courtesy - competence - and ease of repair.
Different types of defects are listed (used for Pareto chart)
Lean is waste reduction - Six Sigma is variation reduction.
Linearity - normality - homoscedasticity - independence.

27. 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).
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Supplier - input - process - output - customer.
No -- only if the process is also capable.

28. A process is operating "in control." Does this mean the customer's requirements are met?
The gap between what management thinks customers want and the process specifications.
Producer risk.
No -- only if the process is also capable.
Outside.

29. When yields decrease - what are the two effects on contribution?
Fewer good units to sell - increased variable cost/unit.
The gap between what is promised and what is delivered.
Represents the behavior of a process
Attribute

30. What is muda
To monitor a process when measurement by attribute is used.
50%
Studying firms with the best performance in a particular area.
Waste.

31. There are two milling machines in the shop. Data has been collected on one to compute control limits for both. This is acceptable SPC practice - true or false and why?
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
False - because each machine will have different natural tolerances.
Outside.
Deming.

32. With Six Sigma capability - how many defects per million opportunities would you see?
3.4 (assuming 1.5 sigma shift in the mean)
Technical quality is the "what" of the service; functional quality is the "how."
The gap between specifications and how service is performed.
Deming.

33. List two appraisal costs.
Through producer/consumer negotiation.
To obtain a certain desirable outcome from the process
Brand image.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

34. Risk Priority Number RPN
Is the way in which the failure is manifested.
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
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Attribute.

35. Define features.
The secondary characteristics of a product; "bells and whistles."
= 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.
The gap between what is promised and what is delivered.

36. What is the role of a green belt?
Large enough to find two of the attribute - on average.
Because the mean and standard deviation are independent of each other.
To be a member of a Six Sigma project team.
A random variable that summarizes the information from the sample(s).

37. If you can only collect categorical data - what type of SPC charting can you do?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
A tool that shows where there is waste in a process.
Critical to quality.
Attribute.

38. ANOVA

39. If a three-stage process has 90% yields at each stage - what is the overall yield?
=sqrt((p*(1-p)/n)
0.9^3 or 72.9%
The ability of a process to consistently meet customer specifications.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

40. Pareto Analysis
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:
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
68%
Is what induces the failure

41. What is poka yoke?
100%
Fewer good units to sell - increased variable cost/unit.
Studying firms with the best performance in a particular area.
Mistake-proofing.

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

43. Affinity Diagrams
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
5%
To mentor/coach (and sometimes train) black belts.
The gap between specifications and how service is performed.

44. Disadvantages of DOE

45. What does Crosby say about benchmarking?
Deming.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
The manager in charge of a process being improved in a Six Sigma project.
Define - measure - analyze - design - verify.

46. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
They move closer to the center line.
Assigns scores to weighted criteria for each project under consideration.
Conformance to specifications.
A random variable that summarizes the information from the sample(s).

47. Uses of regression - Control
To obtain a certain desirable outcome from the process
They move closer to the center line.
Is the way in which the failure is manifested.
The gap between specifications and how service is performed.

48. What is a network diagram?
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
Producer risk.
A diagram that shows the relationships between activities in a project network.
No -- only if the process is also capable.

49. What is the role of a black belt?
Before production starts
To manage the Six Sigma project.
Not necessarily.
To do a capability study for a non-centered process.

50. F value
The ability of a process to consistently meet customer specifications.
F_alpha - df(tr) - df (error)
Hold all input variables constant except one. Observe the response as you vary the single input.
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).