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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 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).
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Critical to quality.
A brainstorming tool that shows the connections between ideas.

2. Define perceived quality (Garvin's framework).
Sampling for SPC is done real time.
The House of Quality.
Brand image.
Lean (or JIT).

3. Daniel Test
A diagram that shows the relationships between activities in a project network.
100%
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:
Organize ideas into meaningful categories by recognizing their underlying similarity

4. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
95%
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:
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
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

5. How does Juran define quality?
Fitness for use.
100%
= 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
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

6. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
A random variable that summarizes the information from the sample(s).
68%
Producer risk.
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).

7. What is CTQ?
Critical to quality.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The gap between what management thinks customers want and the process specifications.

8. When yields decrease - what are the two effects on contribution?
Fewer good units to sell - increased variable cost/unit.
QFD
A tool that shows performance along key dimensions all at once.
Scrap - rework - retest - downtime - yield losses - disposition costs.

9. Regression
= 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
A tool that shows performance along key dimensions all at once.
Represents the behavior of a process
Pleasing to the senses.

10. What is poka yoke?
Fractional factorial designs (orthogonal arrays)
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Mistake-proofing.
Variable.

11. In a Z table - what is Z?
To monitor a process when measurement by variables is used.
The number of standard deviations some value is from the mean.
Is what induces the failure
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

12. Based on what principal can we use the normal distribution assumptions for SPC?
The degree to which a product meets pre-established standards.
Central Limit Theorem
Hold all input variables constant except one. Observe the response as you vary the single input.
Organize ideas into meaningful categories by recognizing their underlying similarity

13. Affinity Diagrams
Fewer good units to sell - increased variable cost/unit.
Mistake-proofing.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Linearity - normality - homoscedasticity - independence.

14. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Is what induces the failure
Attribute
Mean time to failure.
The target number of standard deviations from the mean for specifications.

15. Define performance quality.
They move closer to the center line.
The primary operating characteristics of a product.
A tool that shows performance along key dimensions all at once.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

16. What is process capability?
The ability of a process to consistently meet customer specifications.
Kaoru Ishikawa.
Assigns scores to weighted criteria for each project under consideration.
A tool that shows the physical flows through a space.

17. What are two other names for an Ishikawa diagram?
Large enough to find two of the attribute - on average.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Fishbone - cause-and-effect diagram.
The cycle time required to meet demand.

18. FMEA
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
The US national quality award.
The gap between what management thinks customers want and what customers really want.
Lean is waste reduction - Six Sigma is variation reduction.

19. Regression Analysis
If the Response vs. Levels graph if the response lines are not parallel (crossing)
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Fitness for use.

20. List Garvin's eight dimensions of product quality.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Fractional factorial designs (orthogonal arrays)
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Represents the behavior of a process

21. What is the role of a master black belt?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Not necessarily.
Controlling quality at the source.
To mentor/coach (and sometimes train) black belts.

22. Defect location check sheets
Mistake-proofing.
Mean time to failure.
Inventory = throughput x flow time.
Actual drawings - layouts - maps - etc which show where a defect occurs

23. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Sampling for SPC is done real time.
Mean time to replacement.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Technical quality is the "what" of the service; functional quality is the "how."

24. With Six Sigma capability - how many defects per million opportunities would you see?
The ratio of outputs to inputs; 1-scrap.
A tool that shows where there is waste in a process.
Financial - customer - internal process - innovation and learning.
3.4 (assuming 1.5 sigma shift in the mean)

25. What type of risk is associated with Type II Error?
Attribute.
Can't tell without a Range chart.
Consumer risk.
To manage the Six Sigma project.

26. There are two milling machines in the shop. Data has been collected on one to compute control limits for both. This is acceptable SPC practice - true or false and why?
False - because each machine will have different natural tolerances.
The cycle time required to meet demand.
They move closer to the center line.
Someone who is consistently against virtually everything.

27. What do you do when a process is out of control?
Look for the assignable cause of non-random variation.
Fitness for use.
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
The primary operating characteristics of a product.

28. Define product reliability.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
The secondary characteristics of a product; "bells and whistles."
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Mean time to failure.

29. Define durability.
Mean time to replacement.
The Japanese national quality award.
Is what induces the failure
False - because each machine will have different natural tolerances.

30. In a regression - what does the p value of F tell you?
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).
Method developed by Ishikawa to graphically display the causes of any given problem
Initiated before or at design concept finalization

31. Process occurance ranking
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Deming.
Fractional factorial designs (orthogonal arrays)
10 if Almost impossible to detect

32. What is a run chart?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
No -- only if the process is also capable.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
A time series plot.

33. Failure effect
Brand image.
Mistake-proofing.
What the value of the dependent variable is when the independent variable is zero.
Is the consequence of the failure.

34. What is the Baldrige Award?
68%
Fishbone - cause-and-effect diagram.
Consumer risk.
The US national quality award.

35. In a regression - what does R-square tell you?
Failure Modes and Effects Analysis
Actual drawings - layouts - maps - etc which show where a defect occurs
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Concluding there has not been an effect/change when there has.

36. Simple Regression Analysis (one factor regression model)
Variable.
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.
= 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

37. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
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.
Supplier - input - process - output - customer.
The gap between specifications and how service is performed.

38. Your production process meets customer specifications. Is your process in control?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Not necessarily.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

39. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
Is the consequence of the 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
Upper control limit.

40. Affinity Diagrams
The Japanese national quality award.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Organize ideas into meaningful categories by recognizing their underlying similarity
Observed variation in response is caused by the input

41. In the Service Quality Gap Model - what is Gap 3?
No -- if it is not the same - it can only be worse!
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The gap between specifications and how service is performed.
A tool that shows where there is waste in a process.

42. Design of Experiments (DOE) approach
Is what induces the 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
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

43. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
99.73%
Supplier - input - process - output - customer.
No -- only if the process is also capable.
Causes that lead to a particular effect.

44. Which type of SPC measurement is more precise - variable or attribute?
Concluding there has not been an effect/change when there has.
No -- only if the process is also capable.
Variable.
Technical quality is the "what" of the service; functional quality is the "how."

45. What does the abbreviation UCL stand for?
Failure Modes and Effects Analysis
99.73%
Upper control limit.
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

46. What is a Gantt chart?
Shows the temporal flow of activities in a project network.
Lean is waste reduction - Six Sigma is variation reduction.
The gap between what is promised and what is delivered.
Concluding there has been an effect/change when there has not.

47. Define benchmarking.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
To be a member of a Six Sigma project team.
Blame.
Studying firms with the best performance in a particular area.

48. 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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49. What does a project prioritization matrix do?
= 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
Represents the behavior of a process
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Assigns scores to weighted criteria for each project under consideration.

50. Explain the difference between technical and functional service quality.
The target number of standard deviations from the mean for specifications.
Technical quality is the "what" of the service; functional quality is the "how."
The Japanese national quality award.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).