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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 Garvin's eight dimensions of product quality.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Failure Modes and Effects Analysis

2. DFMEA
Initiated before or at design concept finalization
Fractional factorial designs (orthogonal arrays)
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
The secondary characteristics of a product; "bells and whistles."

3. Which type of SPC measurement is more precise - variable or attribute?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
To monitor a process when measurement by attribute is used.
Variable.
The House of Quality.

4. Define product reliability.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Large enough to find two of the attribute - on average.
Mean time to failure.
p-bar - the long-run percent defective.

5. Complete this quality phrase: 'Fix the process - not the _____.'
Hold all input variables constant except one. Observe the response as you vary the single input.
Mean time to failure.
A tool that shows where there is waste in a process.
Blame.

6. One factor at a time (OFAT)
Observed variation in response is caused by the 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).
Causes that lead to a particular effect.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

7. What is a CAVE man?
Someone who is consistently against virtually everything.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Blame.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

8. What are the 5 Ss?
The manager in charge of a process being improved in a Six Sigma project.
Sort - Set in Order - Shine - Standardize - Sustain
50%
Represents the behavior of a process

9. What is the role of a black belt?
The primary operating characteristics of a product.
Method developed by Ishikawa to graphically display the causes of any given problem
To manage the Six Sigma project.
Taguchi

10. Affinity Diagrams
Critical to quality.
A tool that shows where there is waste in a process.
Outside.
Organize ideas into meaningful categories by recognizing their underlying similarity

11. What is Jidoka?
Can't tell without a Range chart.
Upper control limit.
Controlling quality at the source.
A random variable that summarizes the information from the sample(s).

12. Simple Regression Analysis (one factor regression model)
The number of standard deviations some value is from the mean.
No -- the variation also has to be random and "expected."
A random variable that summarizes the information from the sample(s).
= 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

13. When is Cpk used?
To do a capability study for a non-centered process.
p-bar - the long-run percent defective.
Lower skill requirements - faster - less chance for error.
The gap between what is promised and what is delivered.

14. What is the difference between Lean and Six Sigma?
100%
Represents the behavior of a process
Lean is waste reduction - Six Sigma is variation reduction.
Pleasing to the senses.

15. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Large enough to find two of the attribute - on average.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

16. Affinity Diagrams
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
To monitor a process when measurement by attribute is used.
Lean is waste reduction - Six Sigma is variation reduction.
Scrap - rework - retest - downtime - yield losses - disposition costs.

17. Risk Priority Number RPN
Fishbone - cause-and-effect diagram.
10 if Almost impossible to detect
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Fewer good units to sell - increased variable cost/unit.

18. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Through producer/consumer negotiation.
100%
The manager in charge of a process being improved in a Six Sigma project.
Lower skill requirements - faster - less chance for error.

19. Define serviceability.
Mean time to failure.
Causes that lead to a particular effect.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Speed - courtesy - competence - and ease of repair.

20. What quality tool formally incorporates the voice of the customer?
Actual drawings - layouts - maps - etc which show where a defect occurs
A tool that shows where there is waste in a process.
Variable.
QFD

21. Who developed the fishbone diagram?
Kaoru Ishikawa.
= 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
A diagram that shows the relationships between activities in a project network.
Fewer good units to sell - increased variable cost/unit.

22. Who first studied randomness in industrial processes
Technical quality is the "what" of the service; functional quality is the "how."
Walter A. Shewhart
Producer risk.
No -- the variation also has to be random and "expected."

23. What is a histogram?
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
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

24. Test for Independence
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
To mentor/coach (and sometimes train) black belts.
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 ability of a process to consistently meet customer specifications.

25. Define takt time.
The cycle time required to meet demand.
Outside.
A time series plot.
The manager in charge of a process being improved in a Six Sigma project.

26. What are two other names for an Ishikawa diagram?
An assertion or conjecture concerning one or more populations
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Fishbone - cause-and-effect diagram.
Taguchi

27. What type of risk is associated with Type II Error?
Waste.
Consumer risk.
Financial - customer - internal process - innovation and learning.
Sampling for SPC is done real time.

28. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
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:
100%
No -- the variation also has to be random and "expected."
Causes that lead to a particular effect.

29. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
The secondary characteristics of a product; "bells and whistles."
5%
= yij - y(bar)i --> value minus sum of that treatment (of row)
The gap between specifications and how service is performed.

30. What is a run chart?
The ratio of outputs to inputs; 1-scrap.
The cycle time required to meet demand.
A time series plot.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

31. What are the Five Dimensions of Service Quality?
A random variable that summarizes the information from the sample(s).
Reliability - Assurance - Responsiveness - Tangibles - Empathy
To monitor a process when measurement by attribute is used.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

32. Presence of interaction effect
Studying firms with the best performance in a particular area.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Fitness for use.
Actual drawings - layouts - maps - etc which show where a defect occurs

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

34. TWO-DIMENTIONAL SCATTER PLOT
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Lean is waste reduction - Six Sigma is variation reduction.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Lower skill requirements - faster - less chance for error.

35. Define yield.
A scatterplot.
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 ratio of outputs to inputs; 1-scrap.
A tool that shows the physical flows through a space.

36. Histogram by Hand
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."
Supplier - input - process - output - customer.
Different types of defects are listed (used for Pareto chart)

37. DOE
To do a capability study for a non-centered process.
Conformance to specifications.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
A random variable that summarizes the information from the sample(s).

38. What are the four regression assumptions?
Lower skill requirements - faster - less chance for error.
Linearity - normality - homoscedasticity - independence.
Mean time to replacement.
Concluding there has not been an effect/change when there has.

39. What is muda
False - because each machine will have different natural tolerances.
The gap between specifications and how service is performed.
Waste.
Variable.

40. If a Cp shows that a process is not capable - should you calculate Cpk?
No -- if it is not the same - it can only be worse!
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
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
=sqrt(Σ(x-x-bar)^2)/(n-1))

41. In a Z table - what is Z?
The number of standard deviations some value is from the mean.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Controlling quality at the source.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

42. Taguchi's experimental designs are of this type.
Shows the temporal flow of activities in a project network.
Fractional factorial designs (orthogonal arrays)
Linearity - normality - homoscedasticity - independence.
Concluding there has not been an effect/change when there has.

43. Failure cause
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Is what induces the failure
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The House of Quality.

44. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Lean (or JIT).
Define - measure - analyze - improve - control.
99.73%
Is the way in which the failure is manifested.

45. Why do you need two control charts for variables SPC?
Walter A. Shewhart
=sqrt(Σ(x-x-bar)^2)/(n-1))
p-bar - the long-run percent defective.
Because the mean and standard deviation are independent of each other.

46. If a three-stage process has 90% yields at each stage - what is the overall yield?
Technical quality is the "what" of the service; functional quality is the "how."
Define - measure - analyze - improve - control.
0.9^3 or 72.9%
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

47. Defect check sheets
The target number of standard deviations from the mean for specifications.
3.4 (assuming 1.5 sigma shift in the mean)
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Different types of defects are listed (used for Pareto chart)

48. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
To obtain a certain desirable outcome from the process
99.73%
100%
Walter A. Shewhart

49. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Outside.
Observed variation in response is caused by the input
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
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.

50. For what is an x-bar chart used?
Look for the assignable cause of non-random variation.
To monitor a process when measurement by variables is used.
The US national quality award.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).