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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. What is a Pareto chart?
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
False - because each machine will have different natural tolerances.
A descending order-sorted bar chart with a cumulative percentage line.
Is what induces the failure

2. What are the Five Dimensions of Service Quality?
Lean is waste reduction - Six Sigma is variation reduction.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Assigns scores to weighted criteria for each project under consideration.
Walter A. Shewhart

3. Test for constant variance
To obtain a certain desirable outcome from the process
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.
Is what induces the failure
Fractional factorial designs (orthogonal arrays)

4. What is CTQ?
= yij - y(bar)i --> value minus sum of that treatment (of row)
Speed - courtesy - competence - and ease of repair.
Kaoru Ishikawa.
Critical to quality.

5. How does Juran define quality?
Fitness for use.
The gap between what is promised and what is delivered.
68%
Is what induces the failure

6. What quality tool formally incorporates the voice of the customer?
To obtain a certain desirable outcome from the process
Consumer risk.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
QFD

7. Who first studied randomness in industrial processes
The gap between what management thinks customers want and what customers really want.
99.73%
Walter A. Shewhart
No -- if it is not the same - it can only be worse!

8. What does Crosby say about benchmarking?
Walter A. Shewhart
=sqrt((p*(1-p)/n)
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Prevention and appraisal costs are balanced against internal and external failure.

9. In a regression - what does the coefficient of the intercept tell you
Fractional factorial designs (orthogonal arrays)
Financial - customer - internal process - innovation and learning.
Attribute
What the value of the dependent variable is when the independent variable is zero.

10. Explain the difference between technical and functional service quality.
It's good -- but it's still out of control!
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Technical quality is the "what" of the service; functional quality is the "how."
Concluding there has been an effect/change when there has not.

11. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
68%
Conformance to specifications.
Brand image.
QFD

12. Defect check sheets
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 gap between what is promised and what is delivered.
Concluding there has not been an effect/change when there has.
Different types of defects are listed (used for Pareto chart)

13. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
To monitor a process when measurement by variables is used.
Lower skill requirements - faster - less chance for error.
The secondary characteristics of a product; "bells and whistles."
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

14. What graphical tool is used to show the relationship between two numerical variables?
A scatterplot.
95%
Upper control limit.
Hold all input variables constant except one. Observe the response as you vary the single input.

15. Pareto Analysis
10 if Almost impossible to detect
Outside.
Supplier - input - process - output - customer.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

16. PFMEA
To obtain a certain desirable outcome from the process
Is the way in which the failure is manifested.
Fractional factorial designs (orthogonal arrays)
Before production starts

17. What does SIPOC stand for?
The ratio of outputs to inputs; 1-scrap.
Supplier - input - process - output - customer.
Variable.
Sort - Set in Order - Shine - Standardize - Sustain

18. In a Z table - what is Z?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
The number of standard deviations some value is from the mean.
99.73%
They move closer to the center line.

19. One factor at a time (OFAT)
They move closer to the center line.
Prevention - appraisal - internal failure - external failure.
Observed variation in response is caused by the input
Hold all input variables constant except one. Observe the response as you vary the single input.

20. What is the center line of an X-bar chart?
X-bar-bar
Fractional factorial designs (orthogonal arrays)
It looks to minimize the probability of a failure - or to minimize its effects
The ability of a process to consistently meet customer specifications.

21. Statistical Hypothesis
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
A brainstorming tool that shows the connections between ideas.
QFD
An assertion or conjecture concerning one or more populations

22. What are the four categories of costs in Juran's framework?
Linearity - normality - homoscedasticity - independence.
Prevention - appraisal - internal failure - external failure.
QFD
Causes that lead to a particular effect.

23. Affinity Diagrams
Stratify a particular defect type according to logical criteria
Mean time to failure.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

24. When is Cpk used?
To do a capability study for a non-centered process.
The primary operating characteristics of a product.
The secondary characteristics of a product; "bells and whistles."
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

25. What is a Gantt chart?
To monitor a process when measurement by variables is used.
Lower control limit.
Shows the temporal flow of activities in a project network.
Attribute

26. What is a Gage R&R?
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).
It looks to minimize the probability of a failure - or to minimize its effects
Used to create frequency distribution tally sheets
They move closer to the center line.

27. Risk Priority Number RPN
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).
Prevention - appraisal - internal failure - external failure.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Is what induces the failure

28. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
No -- the variation also has to be random and "expected."
Financial - customer - internal process - innovation and learning.
To do a capability study for a non-centered process.
Lean (or JIT).

29. In the Service Quality Gap Model - what is Gap 5?
The gap between what customers expect and the service they receive.
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
Someone who is consistently against virtually everything.
The US national quality award.

30. In the Service Quality Gap Model - what is Gap 3?
The gap between specifications and how service is performed.
Different types of defects are listed (used for Pareto chart)
X-bar-bar
Represents the behavior of a process

31. What is Type 1 Error?
Organize ideas into meaningful categories by recognizing their underlying similarity
=sqrt(Σ(x-x-bar)^2)/(n-1))
Concluding there has been an effect/change when there has not.
No -- only if the process is also capable.

32. ANOVA

33. 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!
0.9^3 or 72.9%
Scrap - rework - retest - downtime - yield losses - disposition costs.
100%

34. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
50%
Define - measure - analyze - improve - control.
68%
Lean is waste reduction - Six Sigma is variation reduction.

35. Which type of SPC measurement is more precise - variable or attribute?
The number of standard deviations some value is from the mean.
Variable.
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
A tool that shows the physical flows through a space.

36. What type of risk is associated with Type 1 Error?
No -- the variation also has to be random and "expected."
Producer risk.
Represents the behavior of a process
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

37. Regression Analysis
The cycle time required to meet demand.
Fishbone - cause-and-effect diagram.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Mean time to failure.

38. List Garvin's eight dimensions of product quality.
5%
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Variable.
The primary operating characteristics of a product.

39. Failure Mode
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Define - measure - analyze - design - verify.
Deming.
Is the way in which the failure is manifested.

40. A process is operating "in control." Does this mean the customer's requirements are met?
Fishbone - cause-and-effect diagram.
=sqrt((p*(1-p)/n)
No -- only if the process is also capable.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

41. If you can only collect categorical data - what type of SPC charting can you do?
Through producer/consumer negotiation.
Outside.
Attribute.
Lean is waste reduction - Six Sigma is variation reduction.

42. What is process capability?
Conformance to specifications.
The degree to which a product meets pre-established standards.
The ability of a process to consistently meet customer specifications.
p-bar - the long-run percent defective.

43. Non-random patterns (Run Charts)
QFD
Shifts - Trends - Repeating patterns - Correlation with known events
Variable.
A tool that shows performance along key dimensions all at once.

44. What is the role of a master black belt?
Not necessarily.
To mentor/coach (and sometimes train) black belts.
The House of Quality.
Is the consequence of the failure.

45. What is the formula for standard deviation?
The target number of standard deviations from the mean for specifications.
A tool that shows where there is waste in a process.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
=sqrt(Σ(x-x-bar)^2)/(n-1))

46. What does the abbreviation LCL stand for?
Upper control limit.
Before production starts
Lower control limit.
Fishbone - cause-and-effect diagram.

47. Affinity Diagrams
Someone who is consistently against virtually everything.
Variable.
Organize ideas into meaningful categories by recognizing their underlying similarity
0.9^3 or 72.9%

48. What is DMADV?
Rapid improvement process.
To be a member of a Six Sigma project team.
Define - measure - analyze - design - verify.
5%

49. With Six Sigma capability - how many defects per million opportunities would you see?
Someone who is consistently against virtually everything.
Sampling for SPC is done real time.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
3.4 (assuming 1.5 sigma shift in the mean)

50. What is Jidoka?
Controlling quality at the source.
10 for Hazardous without warning 1 for none
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
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.