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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. FMEA
The manager in charge of a process being improved in a Six Sigma project.
To manage the Six Sigma project.
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
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

2. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
No -- if it is not the same - it can only be worse!
A brainstorming tool that shows the connections between ideas.
Taguchi

3. Define conformance quality.
Consumer risk.
The degree to which a product meets pre-established standards.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Prevention - appraisal - internal failure - external failure.

4. Define takt time.
F_alpha - df(tr) - df (error)
Walter A. Shewhart
Blame.
The cycle time required to meet demand.

5. What quality tool formally incorporates the voice of the customer?
QFD
F_alpha - df(tr) - df (error)
p-bar - the long-run percent defective.
= 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

6. Residual
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
The degree to which a product meets pre-established standards.
F_alpha - df(tr) - df (error)
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

7. Process check sheets
To monitor a process when measurement by variables is used.
Used to create frequency distribution tally sheets
=sqrt((p*(1-p)/n)
Blame.

8. Affinity Diagrams
Organize ideas into meaningful categories by recognizing their underlying similarity
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Concluding there has been an effect/change when there has not.
Observed variation in response is caused by the input

9. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
It's good -- but it's still out of control!
X-bar-bar
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

10. Uses of regression
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
They move closer to the center line.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

11. What is DMADV?
3.4 (assuming 1.5 sigma shift in the mean)
Define - measure - analyze - design - verify.
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
X-bar-bar

12. If you have calculated a Cpk - should you also calculate a Cp?
Define - measure - analyze - improve - control.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
= 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
The US national quality award.

13. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Kaoru Ishikawa.
To be a member of a Six Sigma project team.
95%
Sort - Set in Order - Shine - Standardize - Sustain

14. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Lean (or JIT).
No -- only if the process is also capable.
The degree to which a product meets pre-established standards.
A scatterplot.

15. What is a network diagram?
A diagram that shows the relationships between activities in a project network.
Lower control limit.
Rapid improvement process.
Walter A. Shewhart

16. What is the difference between Lean and Six Sigma?
=sqrt((p*(1-p)/n)
Reliability - Assurance - Responsiveness - Tangibles - Empathy
X-bar-bar
Lean is waste reduction - Six Sigma is variation reduction.

17. What are the Five Dimensions of Service Quality?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Financial - customer - internal process - innovation and learning.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

18. What is poka yoke?
Mistake-proofing.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
To mentor/coach (and sometimes train) black belts.
A random variable that summarizes the information from the sample(s).

19. Name the structure associated with Quality Function Deployment.
Attribute.
The House of Quality.
Before production starts
The Japanese national quality award.

20. One factor at a time (OFAT)
Critical to quality.
Observed variation in response is caused by the input
= yij - y(bar)i --> value minus sum of that treatment (of row)
Consumer risk.

21. How are LQL and AQL determined in an acceptance sampling plan?
Through producer/consumer negotiation.
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
It looks to minimize the probability of a failure - or to minimize its effects
The House of Quality.

22. Failure cause
No -- if it is not the same - it can only be worse!
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
It looks to minimize the probability of a failure - or to minimize its effects
Is what induces the failure

23. Affinity Diagrams
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
The gap between what customers expect and the service they receive.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
50%

24. Test for Independence
Scrap - rework - retest - downtime - yield losses - disposition costs.
The House of Quality.
Hold all input variables constant except one. Observe the response as you vary the single input.
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

25. What does a project prioritization matrix do?
Central Limit Theorem
Assigns scores to weighted criteria for each project under consideration.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Scrap - rework - retest - downtime - yield losses - disposition costs.

26. ANOVA

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27. Define benchmarking.
Method developed by Ishikawa to graphically display the causes of any given problem
Studying firms with the best performance in a particular area.
The gap between what management thinks customers want and what customers really want.
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).

28. Define yield.
X-bar-bar
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The ratio of outputs to inputs; 1-scrap.
To mentor/coach (and sometimes train) black belts.

29. How does Juran define quality?
A descending order-sorted bar chart with a cumulative percentage line.
Mean time to replacement.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Fitness for use.

30. Simple Regression Analysis (one factor regression model)
Prevention and appraisal costs are balanced against internal and external 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
Studying firms with the best performance in a particular area.
Represents the behavior of a process

31. What is a histogram?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Conformance to specifications.
The gap between what customers expect and the service they receive.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

32. Disadvantages of DOE

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33. List two appraisal costs.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Concluding there has not been an effect/change when there has.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
99.73%

34. Define product reliability.
Mean time to failure.
A time series plot.
The target number of standard deviations from the mean for specifications.
Look for the assignable cause of non-random variation.

35. What is the center line of an X-bar chart?
No -- only if the process is also capable.
X-bar-bar
Is what induces the failure
They move closer to the center line.

36. Define aesthetic quality.
Consumer risk.
A scatterplot.
Pleasing to the senses.
Defects Per Million Opportunities

37. In the Service Quality Gap Model - what is Gap 4?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
The gap between what is promised and what is delivered.
Kaoru Ishikawa.
Prevention and appraisal costs are balanced against internal and external failure.

38. Defect location check sheets
Actual drawings - layouts - maps - etc which show where a defect occurs
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Outside.
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

39. PFMEA
Before production starts
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Observed variation in response is caused by the input
Linearity - normality - homoscedasticity - independence.

40. What is a Pareto chart?
A descending order-sorted bar chart with a cumulative percentage line.
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
Actual drawings - layouts - maps - etc which show where a defect occurs
Shifts - Trends - Repeating patterns - Correlation with known events

41. What is a run chart?
A time series plot.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Sampling for SPC is done real time.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

42. What does the abbreviation LCL stand for?
To do a capability study for a non-centered process.
Lower control limit.
= yij - y(bar)i --> value minus sum of that treatment (of row)
A diagram that shows the relationships between activities in a project network.

43. What is the 5S model?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
To mentor/coach (and sometimes train) black belts.
Lean (or JIT).
X-bar-bar

44. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Conformance to specifications.
Method developed by Ishikawa to graphically display the causes of any given problem
A time series plot.

45. In a Z table - what is Z?
Pleasing to the senses.
The number of standard deviations some value is from the mean.
Lean (or JIT).
Outside.

46. What is CTQ?
A scatterplot.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A tool that shows performance along key dimensions all at once.
Critical to quality.

47. Risk Priority Number RPN
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
No -- if it is not the same - it can only be worse!
Producer risk.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

48. What is Jidoka?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Controlling quality at the source.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

49. What are the four categories of costs in Juran's framework?
Prevention - appraisal - internal failure - external failure.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Deming.

50. What are the four regression assumptions?
Pleasing to the senses.
Outside.
Prevention - appraisal - internal failure - external failure.
Linearity - normality - homoscedasticity - independence.