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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 external failure.
Attribute
Assigns scores to weighted criteria for each project under consideration.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

2. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Hold all input variables constant except one. Observe the response as you vary the single input.
To be a member of a Six Sigma project team.
Concluding there has been an effect/change when there has not.
Conformance to specifications.

3. What happens to control limits on an SPC chart when sample size is increased?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
They move closer to the center line.
Supplier - input - process - output - customer.
Causes that lead to a particular effect.

4. What is Jidoka?
To monitor a process when measurement by attribute is used.
Controlling quality at the source.
Pleasing to the senses.
No -- the variation also has to be random and "expected."

5. Process occurance ranking
Conformance to specifications.
The gap between what management thinks customers want and the process specifications.
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
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

6. FMEA
The US national quality award.
It looks to minimize the probability of a failure - or to minimize its effects
To obtain a certain desirable outcome from the process
Causes that lead to a particular effect.

7. One factor at a time (OFAT)
Observed variation in response is caused by the input
To manage the Six Sigma project.
0.9^3 or 72.9%
Scrap - rework - retest - downtime - yield losses - disposition costs.

8. What is a spaghetti diagram?
A time series plot.
Critical to quality.
A tool that shows the physical flows through a space.
The gap between what management thinks customers want and the process specifications.

9. If you can only collect categorical data - what type of SPC charting can you do?
The number of standard deviations some value is from the mean.
The ability of a process to consistently meet customer specifications.
Attribute.
The House of Quality.

10. What does the abbreviation LCL stand for?
68%
The primary operating characteristics of a product.
Lower control limit.
Central Limit Theorem

11. What does Crosby say about benchmarking?
Hold all input variables constant except one. Observe the response as you vary the single input.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Brand image.
The number of standard deviations some value is from the mean.

12. Define benchmarking.
Lower control limit.
Studying firms with the best performance in a particular area.
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.

13. What type of risk is associated with Type II Error?
Prevention - appraisal - internal failure - external failure.
Consumer risk.
Can't tell without a Range chart.
It looks to minimize the probability of a failure - or to minimize its effects

14. Effect ranking (Severity of the Defect)
Defects Per Million Opportunities
10 for Hazardous without warning 1 for none
Is what induces the failure
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

15. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
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.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
99.73%
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

16. Test for constant variance
Before production starts
Attribute
Financial - customer - internal process - innovation and learning.
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.

17. What does SIPOC stand for?
Producer risk.
Supplier - input - process - output - customer.
False - because each machine will have different natural tolerances.
The number of standard deviations some value is from the mean.

18. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Actual drawings - layouts - maps - etc which show where a defect occurs
Large enough to find two of the attribute - on average.
To monitor a process when measurement by attribute is used.
5%

19. What is DMADV?
Define - measure - analyze - design - verify.
Mean time to failure.
Speed - courtesy - competence - and ease of repair.
Pleasing to the senses.

20. Test for Independence
F_alpha - df(tr) - df (error)
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
X-bar-bar
Define - measure - analyze - design - verify.

21. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
Actual drawings - layouts - maps - etc which show where a defect occurs
Is the consequence of the failure.
Concluding there has not been an effect/change when there has.

22. Creating a Run Chart
QFD
Fewer good units to sell - increased variable cost/unit.
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).
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

23. Regression
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Fitness for use.
Represents the behavior of a process
To obtain a certain desirable outcome from the process

24. What is a run chart?
The House of Quality.
A time series plot.
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:
Define - measure - analyze - design - verify.

25. Failure cause
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The ability of a process to consistently meet customer specifications.
Through producer/consumer negotiation.
Is what induces the failure

26. What is written on the "spines" of a fishbone diagram?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Causes that lead to a particular effect.
3.4 (assuming 1.5 sigma shift in the mean)
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

27. What is DPMO?
Upper control limit.
Mean time to replacement.
Mean time to failure.
Defects Per Million Opportunities

28. What type of risk is associated with Type 1 Error?
Sampling for SPC is done real time.
Producer risk.
Variable.
The gap between what management thinks customers want and what customers really want.

29. What is the role of a green belt?
To be a member of a Six Sigma project team.
Fitness for use.
An assertion or conjecture concerning one or more populations
The primary operating characteristics of a product.

30. What is muda
To monitor a process when measurement by variables is used.
Before production starts
Brand image.
Waste.

31. One factor at a time (OFAT)
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Initiated before or at design concept finalization
The secondary characteristics of a product; "bells and whistles."
Hold all input variables constant except one. Observe the response as you vary the single input.

32. If you have calculated a Cpk - should you also calculate a Cp?
Attribute
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Method developed by Ishikawa to graphically display the causes of any given problem
p-bar - the long-run percent defective.

33. Complete this quality phrase: 'Fix the process - not the _____.'
The secondary characteristics of a product; "bells and whistles."
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).
Blame.
F_alpha - df(tr) - df (error)

34. Which quality guru developed the concept of loss to society?
Deming.
Taguchi
A tool that shows where there is waste in a process.
False - because each machine will have different natural tolerances.

35. DOE
Linearity - normality - homoscedasticity - independence.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
10 for Hazardous without warning 1 for none
Organize ideas into meaningful categories by recognizing their underlying similarity

36. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Variable.
Not necessarily.
To monitor a process when measurement by attribute is used.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

37. DFMEA
68%
X-bar-bar
Initiated before or at design concept finalization
Hold all input variables constant except one. Observe the response as you vary the single input.

38. What is the formula for standard deviation?
Walter A. Shewhart
=sqrt(Σ(x-x-bar)^2)/(n-1))
A tool that shows performance along key dimensions all at once.
An assertion or conjecture concerning one or more populations

39. What are the four regression assumptions?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Linearity - normality - homoscedasticity - independence.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Attribute

40. What do you do when a process is out of control?
The target number of standard deviations from the mean for specifications.
Because the mean and standard deviation are independent of each other.
Look for the assignable cause of non-random variation.
Is the consequence of the failure.

41. When is Cpk used?
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:
Concluding there has not been an effect/change when there has.
To do a capability study for a non-centered process.
Assigns scores to weighted criteria for each project under consideration.

42. What is the difference between Lean and Six Sigma?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Is the consequence of the failure.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Lean is waste reduction - Six Sigma is variation reduction.

43. What is a histogram?
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
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
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).
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

44. What size should samples be for attribute SPC?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
50%
Large enough to find two of the attribute - on average.
Conformance to specifications.

45. Process check sheets
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Used to create frequency distribution tally sheets
Attribute
Represents the behavior of a process

46. Histogram by Hand
X-bar-bar
Outside.
Fitness for use.
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

47. In the Service Quality Gap Model - what is Gap 3?
Critical to quality.
The gap between specifications and how service is performed.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Inventory = throughput x flow time.

48. To what does the Six in Six Sigma relate?
Can't tell without a Range chart.
False - because each machine will have different natural tolerances.
The target number of standard deviations from the mean for specifications.
99.73%

49. Affinity Diagrams
68%
Mean time to failure.
Organize ideas into meaningful categories by recognizing their underlying similarity
Financial - customer - internal process - innovation and learning.

50. TWO-DIMENTIONAL SCATTER PLOT
What the value of the dependent variable is when the independent variable is zero.
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
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
The House of Quality.