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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. Stratified defect check sheets
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Linearity - normality - homoscedasticity - independence.
A scatterplot.
Stratify a particular defect type according to logical criteria

2. What is a Gage R&R?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
A tool that shows the physical flows through a space.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
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).

3. To what does the Six in Six Sigma relate?
The target number of standard deviations from the mean for specifications.
Fewer good units to sell - increased variable cost/unit.
The gap between what is promised and what is delivered.
To monitor a process when measurement by variables is used.

4. When is Cpk used?
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).
Variable.
To do a capability study for a non-centered process.
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

5. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Prevention and appraisal costs are balanced against internal and external failure.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The ability of a process to consistently meet customer specifications.
Method developed by Ishikawa to graphically display the causes of any given problem

6. For what is a p-chart used?
Large enough to find two of the attribute - on average.
68%
To monitor a process when measurement by attribute is used.
Sort - Set in Order - Shine - Standardize - Sustain

7. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
10 if Almost impossible to detect
A brainstorming tool that shows the connections between ideas.
Attribute
Large enough to find two of the attribute - on average.

8. If a Cp shows that a process is not capable - should you calculate Cpk?
A diagram that shows the relationships between activities in a project network.
68%
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
No -- if it is not the same - it can only be worse!

9. List two appraisal costs.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
To monitor a process when measurement by variables is used.
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).

10. What is a spaghetti diagram?
No -- only if the process is also capable.
A tool that shows the physical flows through a space.
False - because each machine will have different natural tolerances.
Shifts - Trends - Repeating patterns - Correlation with known events

11. What is Type 1 Error?
Lower skill requirements - faster - less chance for error.
Walter A. Shewhart
= yij - y(bar)i --> value minus sum of that treatment (of row)
Concluding there has been an effect/change when there has not.

12. List two components of prevention cost.
Variable.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
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
Central Limit Theorem

13. What are the four regression assumptions?
Workers - machines - materials.
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
Financial - customer - internal process - innovation and learning.
Linearity - normality - homoscedasticity - independence.

14. What graphical tool is used to show the relationship between two numerical variables?
A scatterplot.
A random variable that summarizes the information from the sample(s).
The gap between what is promised and what is delivered.
Assigns scores to weighted criteria for each project under consideration.

15. What does the abbreviation LCL stand for?
Blame.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Lower control limit.
Pleasing to the senses.

16. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Assigns scores to weighted criteria for each project under consideration.
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
Central Limit Theorem
Sampling for SPC is done real time.

17. Advantages of DOE
To obtain a certain desirable outcome from the process
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
The primary operating characteristics of a product.
No -- if it is not the same - it can only be worse!

18. What is the center line of a p-chart?
To do a capability study for a non-centered process.
Financial - customer - internal process - innovation and learning.
p-bar - the long-run percent defective.
To monitor a process when measurement by attribute is used.

19. What is the Baldrige Award?
Failure Modes and Effects Analysis
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
The US national quality award.
Through producer/consumer negotiation.

20. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Because the mean and standard deviation are independent of each other.
Variable.
Prevention and appraisal costs are balanced against internal and external failure.
Brand image.

21. The Test Statistic (TS)
The cycle time required to meet demand.
Rapid improvement process.
Central Limit Theorem
A random variable that summarizes the information from the sample(s).

22. Explain the difference between technical and functional service quality.
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).
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
Is the consequence of the failure.
Technical quality is the "what" of the service; functional quality is the "how."

23. What is muda
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Waste.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
F_alpha - df(tr) - df (error)

24. In the Service Quality Gap Model - what is Gap 3?
No -- only if the process is also capable.
10 for Hazardous without warning 1 for none
Lean (or JIT).
The gap between specifications and how service is performed.

25. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
No -- the variation also has to be random and "expected."
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
95%
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

26. What are the four perspectives of the Balanced Scorecard?
Financial - customer - internal process - innovation and learning.
Upper control limit.
Lower control limit.
Mean time to replacement.

27. One factor at a time (OFAT)
Before production starts
Observed variation in response is caused by the input
Producer risk.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

28. What are the three main categories of assignable cause?
Large enough to find two of the attribute - on average.
Actual drawings - layouts - maps - etc which show where a defect occurs
Workers - machines - materials.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

29. DFMEA
The gap between what management thinks customers want and the process specifications.
Initiated before or at design concept finalization
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Concluding there has been an effect/change when there has not.

30. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
Because the mean and standard deviation are independent of each other.
To mentor/coach (and sometimes train) black belts.
50%

31. Who first studied randomness in industrial processes
Speed - courtesy - competence - and ease of repair.
= 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.
Walter A. Shewhart

32. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Used to create frequency distribution tally sheets
Outside.
Lean (or JIT).

33. Definition of Interaction
Reliability - Assurance - Responsiveness - Tangibles - Empathy
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
X-bar-bar
It looks to minimize the probability of a failure - or to minimize its effects

34. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
99.73%
They move closer to the center line.
QFD
Fishbone - cause-and-effect diagram.

35. Does it ever make sense to accept a job when a process is incapable?
QFD
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Consumer risk.
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

36. What quality tool formally incorporates the voice of the customer?
The target number of standard deviations from the mean for specifications.
QFD
Mean time to failure.
A random variable that summarizes the information from the sample(s).

37. What is the formula for the standard deviation of a proportion?
Initiated before or at design concept finalization
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
Controlling quality at the source.
=sqrt((p*(1-p)/n)

38. In a regression - what does the standard error of the estimate tell you?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Attribute
The gap between what is promised and what is delivered.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

39. Defect check sheets
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Different types of defects are listed (used for Pareto chart)
A tool that shows where there is waste in a process.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

40. What are the four categories of costs in Juran's framework?
Prevention - appraisal - internal failure - external failure.
Waste.
50%
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.

41. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Variable.
100%
Lower skill requirements - faster - less chance for error.

42. What do you do when a process is out of control?
Initiated before or at design concept finalization
Variable.
Sampling for SPC is done real time.
Look for the assignable cause of non-random variation.

43. What is Kaizen?
Different types of defects are listed (used for Pareto chart)
The ability of a process to consistently meet customer specifications.
99.73%
Rapid improvement process.

44. Presence of interaction effect
Define - measure - analyze - design - verify.
Method developed by Ishikawa to graphically display the causes of any given problem
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

45. What is the Deming Prize?
The gap between what management thinks customers want and the process specifications.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Shows the temporal flow of activities in a project network.
The Japanese national quality award.

46. In the Service Quality Gap Model - what is Gap 1?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Outside.
Represents the behavior of a process
The gap between what management thinks customers want and what customers really want.

47. What is the center line of an X-bar chart?
X-bar-bar
Assigns scores to weighted criteria for each project under consideration.
To do a capability study for a non-centered process.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

48. What happens to control limits on an SPC chart when sample size is increased?
To monitor a process when measurement by attribute is used.
They move closer to the center line.
Observed variation in response is caused by the input
The gap between specifications and how service is performed.

49. Uses of regression
To mentor/coach (and sometimes train) black belts.
Look for the assignable cause of non-random variation.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

50. Define performance quality.
The primary operating characteristics of a product.
A tool that shows where there is waste in a process.
Shifts - Trends - Repeating patterns - Correlation with known events
=sqrt(Σ(x-x-bar)^2)/(n-1))