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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 two components of internal failure.
A tool that shows performance along key dimensions all at once.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The Japanese national quality award.

2. 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
Pleasing to the senses.
The manager in charge of a process being improved in a Six Sigma project.
Attribute.

3. What is the role of a master black belt?
No -- if it is not the same - it can only be worse!
Reliability - Assurance - Responsiveness - Tangibles - Empathy
To mentor/coach (and sometimes train) black belts.
Lean is waste reduction - Six Sigma is variation reduction.

4. In the Service Quality Gap Model - what is Gap 2?
Prevention - appraisal - internal failure - external failure.
The gap between what management thinks customers want and the process specifications.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Producer risk.

5. Which quality guru developed the concept of loss to society?
Taguchi
Someone who is consistently against virtually everything.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

6. What is Type II Error?
Rapid improvement process.
Concluding there has not been an effect/change when there has.
p-bar - the long-run percent defective.
Waste.

7. FMEA
It looks to minimize the probability of a failure - or to minimize its effects
They move closer to the center line.
Observed variation in response is caused by the input
Look for the assignable cause of non-random variation.

8. What is a network diagram?
A diagram that shows the relationships between activities in a project network.
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
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Attribute.

9. Define performance quality.
Shifts - Trends - Repeating patterns - Correlation with known events
Reliability - Assurance - Responsiveness - Tangibles - Empathy
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
The primary operating characteristics of a product.

10. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Mean time to failure.
95%
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Controlling quality at the source.

11. In Juran's Cost of Quality model - which categories of costs balance which other categories?
The US national quality award.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Prevention and appraisal costs are balanced against internal and external failure.
A diagram that shows the relationships between activities in a project network.

12. Define features.
No -- the variation also has to be random and "expected."
The secondary characteristics of a product; "bells and whistles."
It's good -- but it's still out of control!
Mistake-proofing.

13. Define yield.
X-bar-bar
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
The ratio of outputs to inputs; 1-scrap.
p-bar - the long-run percent defective.

14. What quality tool formally incorporates the voice of the customer?
Shifts - Trends - Repeating patterns - Correlation with known events
Consumer risk.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
QFD

15. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The cycle time required to meet demand.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

16. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Large enough to find two of the attribute - on average.
The US national quality award.

17. Define benchmarking.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Studying firms with the best performance in a particular area.
It looks to minimize the probability of a failure - or to minimize its effects
Scrap - rework - retest - downtime - yield losses - disposition costs.

18. In the Service Quality Gap Model - what is Gap 1?
Consumer risk.
Conformance to specifications.
The gap between what management thinks customers want and what customers really want.
To monitor a process when measurement by variables is used.

19. List two appraisal costs.
Fishbone - cause-and-effect diagram.
Workers - machines - materials.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
0.9^3 or 72.9%

20. If you can only collect categorical data - what type of SPC charting can you do?
Attribute.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Is the way in which the failure is manifested.
No -- only if the process is also capable.

21. Process check sheets
p-bar - the long-run percent defective.
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
Lean is waste reduction - Six Sigma is variation reduction.
Used to create frequency distribution tally sheets

22. What is the 5S model?
To be a member of a Six Sigma project team.
0.9^3 or 72.9%
A scatterplot.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

23. One factor at a time (OFAT)
50%
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
Observed variation in response is caused by the input
Initiated before or at design concept finalization

24. What is process capability?
Organize ideas into meaningful categories by recognizing their underlying similarity
Outside.
The ability of a process to consistently meet customer specifications.
To be a member of a Six Sigma project team.

25. How are LQL and AQL determined in an acceptance sampling plan?
Through producer/consumer negotiation.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Fishbone - cause-and-effect diagram.
Lean (or JIT).

26. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Producer risk.
The gap between what customers expect and the service they receive.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
No -- the variation also has to be random and "expected."

27. In a regression - what does the coefficient of the intercept tell you
An assertion or conjecture concerning one or more populations
What the value of the dependent variable is when the independent variable is zero.
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 tool that shows the physical flows through a space.

28. For what is a p-chart used?
A descending order-sorted bar chart with a cumulative percentage line.
Critical to quality.
To monitor a process when measurement by attribute is used.
Define - measure - analyze - improve - control.

29. Define takt time.
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:
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
A time series plot.
The cycle time required to meet demand.

30. Define product reliability.
Mean time to failure.
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
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

31. 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).
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
= 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
Financial - customer - internal process - innovation and learning.

32. Explain the difference between technical and functional service quality.
Outside.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
To obtain a certain desirable outcome from the process
Technical quality is the "what" of the service; functional quality is the "how."

33. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
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
Outside.
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
Fitness for use.

34. Who developed the fishbone diagram?
Kaoru Ishikawa.
Conformance to specifications.
Large enough to find two of the attribute - on average.
Taguchi

35. What does Crosby say about benchmarking?
Prevention and appraisal costs are balanced against internal and external failure.
3.4 (assuming 1.5 sigma shift in the mean)
Is the consequence of the failure.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

36. TWO-DIMENTIONAL SCATTER PLOT
The ability of a process to consistently meet customer specifications.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
=sqrt((p*(1-p)/n)

37. What are the Five Dimensions of Service Quality?
Is what induces the failure
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Sampling for SPC is done real time.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

38. What does DMAIC stand for?
Taguchi
The US national quality award.
Define - measure - analyze - improve - control.
Scrap - rework - retest - downtime - yield losses - disposition costs.

39. What is a spaghetti diagram?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Method developed by Ishikawa to graphically display the causes of any given problem
A tool that shows the physical flows through a space.
Concluding there has not been an effect/change when there has.

40. Test for constant variance
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.
Studying firms with the best performance in a particular area.
It's good -- but it's still out of control!
Different types of defects are listed (used for Pareto chart)

41. Disadvantages of DOE

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42. Affinity Diagrams
Controlling quality at the source.
False - because each machine will have different natural tolerances.
Shifts - Trends - Repeating patterns - Correlation with known events
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

43. Uses of regression - Control
An assertion or conjecture concerning one or more populations
Walter A. Shewhart
95%
To obtain a certain desirable outcome from the process

44. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Variable.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Shows the temporal flow of activities in a project network.
= yij - y(bar)i --> value minus sum of that treatment (of row)

45. Define serviceability.
Initiated before or at design concept finalization
Speed - courtesy - competence - and ease of repair.
Shifts - Trends - Repeating patterns - Correlation with known events
Technical quality is the "what" of the service; functional quality is the "how."

46. What is a Gantt chart?
Shows the temporal flow of activities in a project network.
10 if Almost impossible to detect
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Reliability - Assurance - Responsiveness - Tangibles - Empathy

47. What does the abbreviation LCL stand for?
No -- if it is not the same - it can only be worse!
Large enough to find two of the attribute - on average.
Method developed by Ishikawa to graphically display the causes of any given problem
Lower control limit.

48. What is muda
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
10 if Almost impossible to detect
Waste.
Kaoru Ishikawa.

49. Who first studied randomness in industrial processes
Walter A. Shewhart
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
An assertion or conjecture concerning one or more populations
QFD

50. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Attribute
Observed variation in response is caused by the input
A tool that shows where there is waste in a process.