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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. Design of Experiments (DOE) approach
No -- only if the process is also capable.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Represents the behavior of a process
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

2. What does the abbreviation LCL stand for?
The gap between specifications and how service is performed.
Lower control limit.
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
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

3. What quality guru emphasizes management as a system?
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
A tool that shows where there is waste in a process.
To manage the Six Sigma project.
Deming.

4. 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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5. What is the role of a green belt?
The secondary characteristics of a product; "bells and whistles."
Lower control limit.
To be a member of a Six Sigma project team.
95%

6. What is DPMO?
Defects Per Million Opportunities
The cycle time required to meet demand.
Kaoru Ishikawa.
Lower skill requirements - faster - less chance for error.

7. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
100%
No -- the variation also has to be random and "expected."
A tool that shows where there is waste in a process.
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

8. In a Z table - what is Z?
False - because each machine will have different natural tolerances.
The number of standard deviations some value is from the mean.
Workers - machines - materials.
A scatterplot.

9. Failure cause
Rapid improvement process.
Is what induces the failure
A random variable that summarizes the information from the sample(s).
Assigns scores to weighted criteria for each project under consideration.

10. For what is an x-bar chart used?
To monitor a process when measurement by variables is used.
Different types of defects are listed (used for Pareto chart)
p-bar - the long-run percent defective.
0.9^3 or 72.9%

11. In a regression - what does the standard error of the estimate tell you?
The gap between what customers expect and the service they receive.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
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:
Speed - courtesy - competence - and ease of repair.

12. Define durability.
The secondary characteristics of a product; "bells and whistles."
= yij - y(bar)i --> value minus sum of that treatment (of row)
Mean time to replacement.
Kaoru Ishikawa.

13. PFMEA
The Japanese national quality award.
Before production starts
Financial - customer - internal process - innovation and learning.
A tool that shows the physical flows through a space.

14. In the Service Quality Gap Model - what is Gap 3?
The gap between specifications and how service is performed.
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).
Large enough to find two of the attribute - on average.
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:

15. With Six Sigma capability - how many defects per million opportunities would you see?
p-bar - the long-run percent defective.
=sqrt(Σ(x-x-bar)^2)/(n-1))
A tool that shows the physical flows through a space.
3.4 (assuming 1.5 sigma shift in the mean)

16. How does Juran define quality?
The target number of standard deviations from the mean for specifications.
Waste.
Fitness for use.
Failure Modes and Effects Analysis

17. Cause and Effect Diagrams
Define - measure - analyze - improve - control.
Method developed by Ishikawa to graphically display the causes of any given problem
Is the way in which the failure is manifested.
100%

18. What is the 5S model?
Not necessarily.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Variable.
It looks to minimize the probability of a failure - or to minimize its effects

19. 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).
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Causes that lead to a particular effect.
To mentor/coach (and sometimes train) black belts.

20. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
Inventory = throughput x flow time.
Look for the assignable cause of non-random variation.
Lower skill requirements - faster - less chance for error.
100%

21. What is Kaizen?
Is the way in which the failure is manifested.
Define - measure - analyze - design - verify.
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
Rapid improvement process.

22. What does the abbreviation UCL stand for?
Before production starts
Upper control limit.
Pleasing to the senses.
Outside.

23. What is Jidoka?
50%
Controlling quality at the source.
No -- the variation also has to be random and "expected."
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

24. What are the three main categories of assignable cause?
Workers - machines - materials.
To be a member of a Six Sigma project team.
To do a capability study for a non-centered process.
Organize ideas into meaningful categories by recognizing their underlying similarity

25. List two components of external failure.
=sqrt((p*(1-p)/n)
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
A descending order-sorted bar chart with a cumulative percentage line.
The degree to which a product meets pre-established standards.

26. If you can only collect categorical data - what type of SPC charting can you do?
Hold all input variables constant except one. Observe the response as you vary the single input.
Critical to quality.
Attribute.
Can't tell without a Range chart.

27. What is a network diagram?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
A diagram that shows the relationships between activities in a project network.
The US national quality award.
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).

28. A process is operating "in control." Does this mean the customer's requirements are met?
Outside.
No -- only if the process is also capable.
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
Method developed by Ishikawa to graphically display the causes of any given problem

29. What is DMADV?
The secondary characteristics of a product; "bells and whistles."
Mean time to failure.
Not necessarily.
Define - measure - analyze - design - verify.

30. List two components of internal failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Sort - Set in Order - Shine - Standardize - Sustain
Consumer risk.
What the value of the dependent variable is when the independent variable is zero.

31. Disadvantages of DOE

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32. Residual
Shows the temporal flow of activities in a project network.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Failure Modes and Effects Analysis
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

33. Defect check sheets
50%
p-bar - the long-run percent defective.
Assigns scores to weighted criteria for each project under consideration.
Different types of defects are listed (used for Pareto chart)

34. What is the difference between Lean and Six Sigma?
Supplier - input - process - output - customer.
Technical quality is the "what" of the service; functional quality is the "how."
Lean is waste reduction - Six Sigma is variation reduction.
The gap between specifications and how service is performed.

35. Effect ranking (Severity of the Defect)
68%
Brand image.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
10 for Hazardous without warning 1 for none

36. Presence of interaction effect
The gap between what customers expect and the service they receive.
Upper control limit.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Used to create frequency distribution tally sheets

37. FMEA
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
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).
Financial - customer - internal process - innovation and learning.
To monitor a process when measurement by attribute is used.

38. What are the four categories of costs in Juran's framework?
Define - measure - analyze - improve - control.
Prevention - appraisal - internal failure - external failure.
50%
Someone who is consistently against virtually everything.

39. FMEA
It looks to minimize the probability of a failure - or to minimize its effects
The target number of standard deviations from the mean for specifications.
They move closer to the center line.
The cycle time required to meet demand.

40. Test for Independence
Large enough to find two of the attribute - on average.
Central Limit Theorem
Not necessarily.
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

41. List Garvin's eight dimensions of product quality.
The target number of standard deviations from the mean for specifications.
Producer risk.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Not necessarily.

42. To what does the Six in Six Sigma relate?
10 for Hazardous without warning 1 for none
Define - measure - analyze - improve - control.
The target number of standard deviations from the mean for specifications.
The gap between what management thinks customers want and the process specifications.

43. Define perceived quality (Garvin's framework).
Hold all input variables constant except one. Observe the response as you vary the single input.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Brand image.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

44. In the Service Quality Gap Model - what is Gap 1?
The gap between what is promised and what is delivered.
The gap between what management thinks customers want and what customers really want.
Because the mean and standard deviation are independent of each other.
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

45. 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?
False - because each machine will have different natural tolerances.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
=sqrt(Σ(x-x-bar)^2)/(n-1))
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

46. What is a spaghetti diagram?
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) Plot a Line chart of the data in time sequence 2) Draw a line at the median
A tool that shows the physical flows through a space.
No -- only if the process is also capable.

47. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
10 if Almost impossible to detect
Deming.
Prevention and appraisal costs are balanced against internal and external failure.
Variable.

48. In the Service Quality Gap Model - what is Gap 4?
100%
Attribute
The gap between what is promised and what is delivered.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

49. Daniel Test
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
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:
Variable.
Fitness for use.

50. What is the formula for the standard deviation of a proportion?
Linearity - normality - homoscedasticity - independence.
=sqrt((p*(1-p)/n)
A random variable that summarizes the information from the sample(s).
Is what induces the failure