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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. List two appraisal costs.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Technical quality is the "what" of the service; functional quality is the "how."
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Conformance to specifications.

2. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Lower skill requirements - faster - less chance for error.
3.4 (assuming 1.5 sigma shift in the mean)
Large enough to find two of the attribute - on average.
Studying firms with the best performance in a particular area.

3. Simple Regression Analysis (one factor regression model)
Scrap - rework - retest - downtime - yield losses - disposition costs.
Used to create frequency distribution tally sheets
= 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
Sort - Set in Order - Shine - Standardize - Sustain

4. What size should samples be for attribute SPC?
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).
Because the mean and standard deviation are independent of each other.
Large enough to find two of the attribute - on average.
They move closer to the center line.

5. Based on what principal can we use the normal distribution assumptions for SPC?
Blame.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Central Limit Theorem
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

6. Define takt time.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The cycle time required to meet demand.
The House of Quality.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

7. Cause and Effect Diagrams
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Method developed by Ishikawa to graphically display the causes of any given problem
The target number of standard deviations from the mean for specifications.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

8. With Six Sigma capability - how many defects per million opportunities would you see?
Lower control limit.
Studying firms with the best performance in a particular area.
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

9. If you have calculated a Cpk - should you also calculate a Cp?
F_alpha - df(tr) - df (error)
Is what induces the failure
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
5%

10. Define features.
Not necessarily.
The secondary characteristics of a product; "bells and whistles."
Through producer/consumer negotiation.
The gap between what customers expect and the service they receive.

11. 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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12. What is Kaizen?
Assigns scores to weighted criteria for each project under consideration.
0.9^3 or 72.9%
Rapid improvement process.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

13. Name the structure associated with Quality Function Deployment.
Defects Per Million Opportunities
To mentor/coach (and sometimes train) black belts.
The gap between what management thinks customers want and the process specifications.
The House of Quality.

14. FMEA
Mistake-proofing.
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
68%
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

15. Affinity Diagrams
Prevention and appraisal costs are balanced against internal and 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:
Mean time to replacement.
Organize ideas into meaningful categories by recognizing their underlying similarity

16. What is written on the "spines" of a fishbone diagram?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Upper control limit.
X-bar-bar
Causes that lead to a particular effect.

17. In the Service Quality Gap Model - what is Gap 4?
The gap between what is promised and what is delivered.
The Japanese national quality award.
Is what induces the failure
F_alpha - df(tr) - df (error)

18. Uses of regression
Brand image.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Fractional factorial designs (orthogonal arrays)
95%

19. Your production process meets customer specifications. Is your process in control?
Rapid improvement process.
Fitness for use.
Not necessarily.
Fewer good units to sell - increased variable cost/unit.

20. In a regression - what does the p value of F tell you?
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).
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
What the value of the dependent variable is when the independent variable is zero.

21. One factor at a time (OFAT)
Through producer/consumer negotiation.
Observed variation in response is caused by the input
Supplier - input - process - output - customer.
The Japanese national quality award.

22. What is a histogram?
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:
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

23. What is Type 1 Error?
Taguchi
Concluding there has been an effect/change when there has not.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The gap between what customers expect and the service they receive.

24. For what is an x-bar chart used?
Attribute
To monitor a process when measurement by variables is used.
Conformance to specifications.
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. Process occurance ranking
Outside.
Rapid improvement process.
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
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

26. What are the three main categories of assignable cause?
The primary operating characteristics of a product.
The gap between what is promised and what is delivered.
Not necessarily.
Workers - machines - materials.

27. F value
F_alpha - df(tr) - df (error)
Not necessarily.
A scatterplot.
Fractional factorial designs (orthogonal arrays)

28. What is a spaghetti diagram?
The primary operating characteristics of a product.
A tool that shows the physical flows through a space.
A tool that shows performance along key dimensions all at once.
Before production starts

29. What quality guru emphasizes management as a system?
Defects Per Million Opportunities
Deming.
Used to create frequency distribution tally sheets
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

30. What is the formula for the standard deviation of a proportion?
Because the mean and standard deviation are independent of each other.
=sqrt((p*(1-p)/n)
To monitor a process when measurement by attribute is used.
Lower control limit.

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

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32. Define benchmarking.
Studying firms with the best performance in a particular area.
Someone who is consistently against virtually everything.
Brand image.
Not necessarily.

33. What type of risk is associated with Type 1 Error?
Stratify a particular defect type according to logical criteria
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Producer risk.
No -- the variation also has to be random and "expected."

34. What is a CAVE man?
Someone who is consistently against virtually everything.
It looks to minimize the probability of a failure - or to minimize its effects
The gap between what management thinks customers want and what customers really want.
Because the mean and standard deviation are independent of each other.

35. What is Value Stream Mapping?
The gap between what is promised and what is delivered.
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:
A tool that shows where there is waste in a process.
The degree to which a product meets pre-established standards.

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).
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Look for the assignable cause of non-random variation.
Waste.

37. 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
Define - measure - analyze - improve - control.
10 for Hazardous without warning 1 for none

38. Statistical Hypothesis
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Shows the temporal flow of activities in a project network.
An assertion or conjecture concerning one or more populations
Causes that lead to a particular effect.

39. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
A time series plot.
QFD
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
No -- the variation also has to be random and "expected."

40. What is the center line of an X-bar chart?
What the value of the dependent variable is when the independent variable is zero.
Producer risk.
Lower control limit.
X-bar-bar

41. What happens to control limits on an SPC chart when sample size is increased?
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
They move closer to the center line.
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
Studying firms with the best performance in a particular area.

42. What is the Baldrige Award?
Initiated before or at design concept finalization
Prevention and appraisal costs are balanced against internal and external failure.
=sqrt((p*(1-p)/n)
The US national quality award.

43. Does it ever make sense to accept a job when a process is incapable?
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
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
No -- if it is not the same - it can only be worse!
Look for the assignable cause of non-random variation.

44. Regression
A tool that shows where there is waste in a process.
The ratio of outputs to inputs; 1-scrap.
Represents the behavior of a process
No -- only if the process is also capable.

45. What is the role of a green belt?
To be a member of a Six Sigma project team.
Attribute
To do a capability study for a non-centered process.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

46. Stratified defect check sheets
Mean time to replacement.
To do a capability study for a non-centered process.
Stratify a particular defect type according to logical criteria
Mean time to failure.

47. What quality tool formally incorporates the voice of the customer?
QFD
A tool that shows the physical flows through a space.
Someone who is consistently against virtually everything.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

48. Failure cause
Is what induces the failure
It's good -- but it's still out of control!
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
A diagram that shows the relationships between activities in a project network.

49. Risk Priority Number RPN
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
A descending order-sorted bar chart with a cumulative percentage line.
Concluding there has not been an effect/change when there has.

50. 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?
Central Limit Theorem
False - because each machine will have different natural tolerances.
Mean time to replacement.
10 for Hazardous without warning 1 for none