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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.
Fewer good units to sell - increased variable cost/unit.
Mistake-proofing.
5%
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

2. Detection Criteria Ranking
Outside.
10 if Almost impossible to detect
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.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

3. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Defects Per Million Opportunities
Prevention and appraisal costs are balanced against internal and external failure.
To monitor a process when measurement by variables is used.

4. FMEA
Is the consequence of the failure.
Conformance to specifications.
It looks to minimize the probability of a failure - or to minimize its effects
Blame.

5. What is DPMO?
Define - measure - analyze - design - verify.
Speed - courtesy - competence - and ease of repair.
Defects Per Million Opportunities
Prevention and appraisal costs are balanced against internal and external failure.

6. Your production process meets customer specifications. Is your process in control?
Not necessarily.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
= 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
Consumer risk.

7. What is poka yoke?
Stratify a particular defect type according to logical criteria
Defects Per Million Opportunities
Mistake-proofing.
Technical quality is the "what" of the service; functional quality is the "how."

8. What happens to control limits on an SPC chart when sample size is increased?
No -- the variation also has to be random and "expected."
They move closer to the center line.
Rapid improvement process.
To obtain a certain desirable outcome from the process

9. How are LQL and AQL determined in an acceptance sampling plan?
It's good -- but it's still out of control!
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
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
Through producer/consumer negotiation.

10. What is Type II Error?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Look for the assignable cause of non-random variation.
Concluding there has not been an effect/change when there has.

11. Who is a process owner?
Deming.
The manager in charge of a process being improved in a Six Sigma project.
p-bar - the long-run percent defective.
Actual drawings - layouts - maps - etc which show where a defect occurs

12. What is the 5S model?
Workers - machines - materials.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
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
F_alpha - df(tr) - df (error)

13. What does DMAIC stand for?
Is the way in which the failure is manifested.
A brainstorming tool that shows the connections between ideas.
Define - measure - analyze - improve - control.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

14. Pareto Analysis
Upper control limit.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
It looks to minimize the probability of a failure - or to minimize its effects
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

15. List two components of prevention cost.
Is what induces the failure
Workers - machines - materials.
To be a member of a Six Sigma project team.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

16. What is the center line of a p-chart?
X-bar-bar
100%
Variable.
p-bar - the long-run percent defective.

17. What are the four regression assumptions?
QFD
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Linearity - normality - homoscedasticity - independence.
Upper control limit.

18. What is Value Stream Mapping?
Pleasing to the senses.
Shifts - Trends - Repeating patterns - Correlation with known events
A tool that shows where there is waste in a process.
50%

19. Test for constant variance
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Causes that lead to a particular effect.
Not necessarily.
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.

20. Presence of interaction effect
False - because each machine will have different natural tolerances.
The number of standard deviations some value is from the mean.
The primary operating characteristics of a product.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

21. 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?
Mean time to failure.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
False - because each machine will have different natural tolerances.

22. In the Service Quality Gap Model - what is Gap 2?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Is the way in which the failure is manifested.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The gap between what management thinks customers want and the process specifications.

23. Process check sheets
No -- the variation also has to be random and "expected."
A tool that shows the physical flows through a space.
Conformance to specifications.
Used to create frequency distribution tally sheets

24. Define aesthetic quality.
Pleasing to the senses.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
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 House of Quality.

25. What is a histogram?
To mentor/coach (and sometimes train) black belts.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Define - measure - analyze - improve - control.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

26. Define benchmarking.
Sort - Set in Order - Shine - Standardize - Sustain
To monitor a process when measurement by variables is used.
Studying firms with the best performance in a particular area.
10 if Almost impossible to detect

27. In the Service Quality Gap Model - what is Gap 1?
Observed variation in response is caused by the input
Not necessarily.
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 gap between what management thinks customers want and what customers really want.

28. Test for Independence
Failure Modes and Effects Analysis
Shifts - Trends - Repeating patterns - Correlation with known events
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
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

29. What does the abbreviation LCL stand for?
Lower control limit.
68%
Speed - courtesy - competence - and ease of repair.
5%

30. Name the structure associated with Quality Function Deployment.
Waste.
The House of Quality.
It looks to minimize the probability of a failure - or to minimize its effects
Represents the behavior of a process

31. What is CTQ?
QFD
Brand image.
Critical to quality.
=sqrt((p*(1-p)/n)

32. Advantages of DOE
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
A tool that shows performance along key dimensions all at once.
Represents the behavior of a process
Hold all input variables constant except one. Observe the response as you vary the single input.

33. In the Service Quality Gap Model - what is Gap 3?
Defects Per Million Opportunities
The gap between specifications and how service is performed.
= 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
Before production starts

34. One factor at a time (OFAT)
Observed variation in response is caused by the input
= yij - y(bar)i --> value minus sum of that treatment (of row)
Shows the temporal flow of activities in a project network.
99.73%

35. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
To monitor a process when measurement by variables is used.
5%

36. Who first studied randomness in industrial processes
The gap between what customers expect and the service they receive.
Walter A. Shewhart
Attribute
Shows the temporal flow of activities in a project network.

37. List two appraisal costs.
A diagram that shows the relationships between activities in a project network.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Controlling quality at the source.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

38. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Fewer good units to sell - increased variable cost/unit.
The gap between what management thinks customers want and the process specifications.
99.73%
Someone who is consistently against virtually everything.

39. What is the role of a green belt?
Define - measure - analyze - design - verify.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
To be a member of a Six Sigma project team.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

40. Effect ranking (Severity of the Defect)
Observed variation in response is caused by the input
10 for Hazardous without warning 1 for none
Causes that lead to a particular effect.
Deming.

41. In a regression - what does the standard error of the estimate tell you?
Large enough to find two of the attribute - on average.
Lean is waste reduction - Six Sigma is variation reduction.
Upper control limit.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

42. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Attribute
Is what induces the failure
The US national quality award.
Waste.

43. What does Crosby say about benchmarking?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
The degree to which a product meets pre-established standards.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Before production starts

44. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
F_alpha - df(tr) - df (error)
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
68%
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

45. For what is an x-bar chart used?
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).
To manage the Six Sigma project.
Is the way in which the failure is manifested.

46. What do you do when a process is out of control?
Lean is waste reduction - Six Sigma is variation reduction.
Actual drawings - layouts - maps - etc which show where a defect occurs
Look for the assignable cause of non-random variation.
The US national quality award.

47. What is the role of a master black belt?
To mentor/coach (and sometimes train) black belts.
What the value of the dependent variable is when the independent variable is zero.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Controlling quality at the source.

48. What is written on the "spines" of a fishbone diagram?
F_alpha - df(tr) - df (error)
Sort - Set in Order - Shine - Standardize - Sustain
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:
Causes that lead to a particular effect.

49. What is the difference between Lean and Six Sigma?
Lean is waste reduction - Six Sigma is variation reduction.
Concluding there has not been an effect/change when there has.
No -- only if the process is also capable.
50%

50. ANOVA

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