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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. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Causes that lead to a particular effect.
Attribute.
100%

2. What is the difference between Lean and Six Sigma?
The number of standard deviations some value is from the mean.
An assertion or conjecture concerning one or more populations
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Lean is waste reduction - Six Sigma is variation reduction.

3. In the Service Quality Gap Model - what is Gap 2?
To monitor a process when measurement by attribute is used.
Because the mean and standard deviation are independent of each other.
The number of standard deviations some value is from the mean.
The gap between what management thinks customers want and the process specifications.

4. What type of risk is associated with Type II Error?
The secondary characteristics of a product; "bells and whistles."
Lean is waste reduction - Six Sigma is variation reduction.
Consumer risk.
=sqrt(Σ(x-x-bar)^2)/(n-1))

5. What is a network diagram?
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.
The gap between what management thinks customers want and what customers really want.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

6. What is a Gage R&R?
0.9^3 or 72.9%
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
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).
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

7. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
Concluding there has not been an effect/change when there has.
Central Limit Theorem
If the Response vs. Levels graph if the response lines are not parallel (crossing)

8. What is muda
Workers - machines - materials.
A tool that shows the physical flows through a space.
=sqrt((p*(1-p)/n)
Waste.

9. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
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).
Not necessarily.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

10. What does a project prioritization matrix do?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Shifts - Trends - Repeating patterns - Correlation with known events
Sampling for SPC is done real time.
Assigns scores to weighted criteria for each project under consideration.

11. Which type of SPC measurement is more precise - variable or attribute?
Fitness for use.
Variable.
Outside.
Workers - machines - materials.

12. What are the four regression assumptions?
Rapid improvement process.
Controlling quality at the source.
X-bar-bar
Linearity - normality - homoscedasticity - independence.

13. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
Scrap - rework - retest - downtime - yield losses - disposition costs.
Prevention and appraisal costs are balanced against internal and external failure.
Before production starts

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

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15. What is the Baldrige Award?
To do a capability study for a non-centered process.
Attribute.
A tool that shows performance along key dimensions all at once.
The US national quality award.

16. What is a dashboard?
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 chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
A tool that shows performance along key dimensions all at once.
The gap between what management thinks customers want and the process specifications.

17. Simple Regression Analysis (one factor regression model)
The ability of a process to consistently meet customer specifications.
A brainstorming tool that shows the connections between ideas.
= 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
Attribute

18. Define durability.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
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).
Mean time to replacement.
Method developed by Ishikawa to graphically display the causes of any given problem

19. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
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
The gap between what management thinks customers want and the process specifications.
Lean (or JIT).
Is the way in which the failure is manifested.

20. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Blame.
Upper control limit.
The target number of standard deviations from the mean for specifications.
Attribute

21. Cause and Effect Diagrams
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Method developed by Ishikawa to graphically display the causes of any given problem
10 for Hazardous without warning 1 for none
Actual drawings - layouts - maps - etc which show where a defect occurs

22. What does the abbreviation LCL stand for?
Technical quality is the "what" of the service; functional quality is the "how."
Lower control limit.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Not necessarily.

23. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
100%
A tool that shows where there is waste in a process.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

24. What percentage of a normal distribution lies above the mean?
Fractional factorial designs (orthogonal arrays)
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%
50%

25. What is Type 1 Error?
Mean time to failure.
Linearity - normality - homoscedasticity - independence.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Concluding there has been an effect/change when there has not.

26. What is a Pareto chart?
A descending order-sorted bar chart with a cumulative percentage line.
Kaoru Ishikawa.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
= 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

27. 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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28. What is a Gantt chart?
Producer risk.
Mean time to replacement.
Shows the temporal flow of activities in a project network.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

29. For what is an x-bar chart used?
Method developed by Ishikawa to graphically display the causes of any given problem
To monitor a process when measurement by variables is used.
A tool that shows performance along key dimensions all at once.
Because the mean and standard deviation are independent of each other.

30. What is the role of a black belt?
Can't tell without a Range chart.
The target number of standard deviations from the mean for specifications.
To obtain a certain desirable outcome from the process
To manage the Six Sigma project.

31. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Taguchi
To monitor a process when measurement by variables is used.
95%

32. In a Z table - what is Z?
The number of standard deviations some value is from the mean.
Look for the assignable cause of non-random variation.
Waste.
Someone who is consistently against virtually everything.

33. FMEA
Mean time to failure.
No -- only if the process is also capable.
A tool that shows where there is waste in a process.
It looks to minimize the probability of a failure - or to minimize its effects

34. List Garvin's eight dimensions of product quality.
Before production starts
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
They move closer to the center line.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

35. What is a CAVE man?
Someone who is consistently against virtually everything.
The House of Quality.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Taguchi

36. Why do you need two control charts for variables SPC?
Conformance to specifications.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Attribute
Because the mean and standard deviation are independent of each other.

37. What is the center line of a p-chart?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The gap between specifications and how service is performed.
p-bar - the long-run percent defective.
The primary operating characteristics of a product.

38. In a regression - what does R-square tell you?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
A tool that shows where there is waste in a process.
What the value of the dependent variable is when the independent variable is zero.
The target number of standard deviations from the mean for specifications.

39. Non-random patterns (Run Charts)
The House of Quality.
It looks to minimize the probability of a failure - or to minimize its effects
Shifts - Trends - Repeating patterns - Correlation with known events
A random variable that summarizes the information from the sample(s).

40. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
100%
Before production starts
68%
= 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

41. A process is operating "in control." Does this mean the customer's requirements are met?
Failure Modes and Effects Analysis
No -- only if the process is also capable.
The target number of standard deviations from the mean for specifications.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

42. Regression
Represents the behavior of a process
Through producer/consumer negotiation.
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).
Taguchi

43. Taguchi's experimental designs are of this type.
A tool that shows the physical flows through a space.
It's good -- but it's still out of control!
Not necessarily.
Fractional factorial designs (orthogonal arrays)

44. F value
A random variable that summarizes the information from the sample(s).
Studying firms with the best performance in a particular area.
F_alpha - df(tr) - df (error)
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

45. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Speed - courtesy - competence - and ease of repair.
Sort - Set in Order - Shine - Standardize - Sustain
Technical quality is the "what" of the service; functional quality is the "how."
Prevention and appraisal costs are balanced against internal and external failure.

46. Define serviceability.
Financial - customer - internal process - innovation and learning.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Lower control limit.
Speed - courtesy - competence - and ease of repair.

47. What size should samples be for attribute SPC?
Large enough to find two of the attribute - on average.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
It looks to minimize the probability of a failure - or to minimize its effects
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

48. Process occurance ranking
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Define - measure - analyze - improve - control.
Because the mean and standard deviation are independent of each other.
The primary operating characteristics of a product.

49. DFMEA
Defects Per Million Opportunities
False - because each machine will have different natural tolerances.
Initiated before or at design concept finalization
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

50. Define perceived quality (Garvin's framework).
Controlling quality at the source.
Mean time to replacement.
Brand image.
Used to create frequency distribution tally sheets