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Six Sigma

Subjects : certifications, six-sigma, business-skills

Instructions:

Answer 50 questions in 15 minutes.
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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 components of internal failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Look for the assignable cause of non-random variation.
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).
A diagram that shows the relationships between activities in a project network.

2. What is muda
Waste.
The Japanese national quality award.
To do a capability study for a non-centered process.
Initiated before or at design concept finalization

3. What is Type II Error?
The US national quality award.
Concluding there has not been an effect/change when there has.
10 for Hazardous without warning 1 for none
A brainstorming tool that shows the connections between ideas.

4. DOE
The cycle time required to meet demand.
Pleasing to the senses.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Mean time to replacement.

5. What type of risk is associated with Type 1 Error?
Studying firms with the best performance in a particular area.
95%
Producer risk.
Variable.

6. What is poka yoke?
Linearity - normality - homoscedasticity - independence.
To be a member of a Six Sigma project team.
Mistake-proofing.
Rapid improvement process.

7. Process check sheets
Used to create frequency distribution tally sheets
Upper control limit.
Lean (or JIT).
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

8. PFMEA
10 if Almost impossible to detect
Prevention - appraisal - internal failure - external failure.
Before production starts
A diagram that shows the relationships between activities in a project network.

9. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
Variable.
Studying firms with the best performance in a particular area.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

10. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
A diagram that shows the relationships between activities in a project network.
The House of Quality.

11. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Rapid improvement process.
Variable.
10 if Almost impossible to detect
95%

12. What does Crosby say about benchmarking?
Not necessarily.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A diagram that shows the relationships between activities in a project network.

13. Why do you need two control charts for variables SPC?
Consumer risk.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
To do a capability study for a non-centered process.
Because the mean and standard deviation are independent of each other.

14. List two components of prevention cost.
Prevention and appraisal costs are balanced against internal and external failure.
The House of Quality.
F_alpha - df(tr) - df (error)
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

15. What is the difference between Lean and Six Sigma?
The US national quality award.
Linearity - normality - homoscedasticity - independence.
Financial - customer - internal process - innovation and learning.
Lean is waste reduction - Six Sigma is variation reduction.

16. Define product reliability.
0.9^3 or 72.9%
Lower control limit.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Mean time to failure.

17. What is Type 1 Error?
Conformance to specifications.
Concluding there has been an effect/change when there has not.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Variable.

18. What is the role of a master black belt?
To mentor/coach (and sometimes train) black belts.
Taguchi
Conformance to specifications.
Central Limit Theorem

19. If a three-stage process has 90% yields at each stage - what is the overall yield?
0.9^3 or 72.9%
Waste.
100%
Concluding there has not been an effect/change when there has.

20. What is the center line of a p-chart?
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
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
p-bar - the long-run percent defective.
10 for Hazardous without warning 1 for none

21. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
No -- the variation also has to be random and "expected."
It looks to minimize the probability of a failure - or to minimize its effects
Fewer good units to sell - increased variable cost/unit.

22. For what is a p-chart used?
Conformance to specifications.
To monitor a process when measurement by attribute is used.
Outside.
The ratio of outputs to inputs; 1-scrap.

23. With Six Sigma capability - how many defects per million opportunities would you see?
Taguchi
3.4 (assuming 1.5 sigma shift in the mean)
Fitness for use.
No -- only if the process is also capable.

24. What is FMEA?
Failure Modes and Effects Analysis
Central Limit Theorem
A diagram that shows the relationships between activities in a project network.
The gap between what management thinks customers want and the process specifications.

25. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Organize ideas into meaningful categories by recognizing their underlying similarity
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).
Outside.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

26. FMEA
Can't tell without a Range chart.
Walter A. Shewhart
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
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:

27. Based on what principal can we use the normal distribution assumptions for SPC?
Fitness for use.
Shifts - Trends - Repeating patterns - Correlation with known events
Assigns scores to weighted criteria for each project under consideration.
Central Limit Theorem

28. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
Because the mean and standard deviation are independent of each other.
Sampling for SPC is done real time.
Fishbone - cause-and-effect diagram.

29. 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.
Lower control limit.
Workers - machines - materials.
Central Limit Theorem

30. What is a dashboard?
A tool that shows performance along key dimensions all at once.
Attribute
Represents the behavior of a process
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).

31. Failure cause
A random variable that summarizes the information from the sample(s).
To monitor a process when measurement by variables is used.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Is what induces the failure

32. Failure Mode
3.4 (assuming 1.5 sigma shift in the mean)
The gap between what management thinks customers want and what customers really want.
Waste.
Is the way in which the failure is manifested.

33. What quality tool formally incorporates the voice of the customer?
A brainstorming tool that shows the connections between ideas.
Fishbone - cause-and-effect diagram.
QFD
Controlling quality at the source.

34. 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).
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Stratify a particular defect type according to logical criteria
Assigns scores to weighted criteria for each project under consideration.

35. What is a Pareto chart?
Because the mean and standard deviation are independent of each other.
A descending order-sorted bar chart with a cumulative percentage line.
Attribute
The gap between what management thinks customers want and what customers really want.

36. Defect location check sheets
Technical quality is the "what" of the service; functional quality is the "how."
Stratify a particular defect type according to logical criteria
Define - measure - analyze - design - verify.
Actual drawings - layouts - maps - etc which show where a defect occurs

37. What graphical tool is used to show the relationship between two numerical variables?
A scatterplot.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Studying firms with the best performance in a particular area.
QFD

38. When is Cpk used?
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:
Studying firms with the best performance in a particular area.
To do a capability study for a non-centered process.
Represents the behavior of a process

39. What is DPMO?
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
The number of standard deviations some value is from the mean.
95%
Defects Per Million Opportunities

40. Stratified defect check sheets
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Waste.
Stratify a particular defect type according to logical criteria
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:

41. List two appraisal costs.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The US national quality award.
Shifts - Trends - Repeating patterns - Correlation with known events
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

42. For what is an x-bar chart used?
To monitor a process when measurement by variables is used.
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
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
It looks to minimize the probability of a failure - or to minimize its effects

43. If you can only collect categorical data - what type of SPC charting can you do?
Conformance to specifications.
Attribute.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

44. Who developed the fishbone diagram?
To monitor a process when measurement by attribute is used.
Linearity - normality - homoscedasticity - independence.
Kaoru Ishikawa.
Brand image.

45. What is an affinity diagram?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A brainstorming tool that shows the connections between ideas.
The gap between what management thinks customers want and what customers really want.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

46. Pareto Analysis
The gap between specifications and how service is performed.
A tool that shows the physical flows through a space.
The Japanese national quality award.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

47. In a regression - what does the p value of F tell you?
Shows the temporal flow of activities in a project network.
Financial - customer - internal process - innovation and learning.
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).
To monitor a process when measurement by variables is used.

48. Define takt time.
Deming.
The cycle time required to meet demand.
Is what induces the failure
= 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

49. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Blame.
A scatterplot.
Define - measure - analyze - design - verify.
99.73%

50. List two components of external failure.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Lean (or JIT).
The Japanese national quality award.
Mistake-proofing.

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