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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 quality guru emphasizes management as a system?
Deming.
Outside.
The ratio of outputs to inputs; 1-scrap.
100%

2. What are the Five Dimensions of Service Quality?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Causes that lead to a particular effect.
Deming.
A tool that shows the physical flows through a space.

3. What is FMEA?
Technical quality is the "what" of the service; functional quality is the "how."
Deming.
Failure Modes and Effects Analysis
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

4. If a three-stage process has 90% yields at each stage - what is the overall yield?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
0.9^3 or 72.9%
The US national quality award.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

5. What size should samples be for attribute SPC?
The gap between what is promised and what is delivered.
Upper control limit.
Causes that lead to a particular effect.
Large enough to find two of the attribute - on average.

6. What are the four categories of costs in Juran's framework?
Prevention - appraisal - internal failure - external failure.
Attribute.
The gap between what management thinks customers want and what customers really want.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

7. What type of risk is associated with Type II Error?
Concluding there has not been an effect/change when there has.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Financial - customer - internal process - innovation and learning.
Consumer risk.

8. Define conformance quality.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
To mentor/coach (and sometimes train) black belts.
Taguchi
The degree to which a product meets pre-established standards.

9. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
The primary operating characteristics of a product.
The ability of a process to consistently meet customer specifications.
Is the way in which the failure is manifested.

10. Test for constant variance
Fitness for use.
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.
False - because each machine will have different natural tolerances.
Shifts - Trends - Repeating patterns - Correlation with known events

11. List two components of internal failure.
Lower control limit.
A tool that shows performance along key dimensions all at once.
Scrap - rework - retest - downtime - yield losses - disposition costs.
The ratio of outputs to inputs; 1-scrap.

12. DFMEA
Conformance to specifications.
10 for Hazardous without warning 1 for none
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Initiated before or at design concept finalization

13. In a regression - what does the p value of F tell you?
A scatterplot.
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).
Upper control limit.
A brainstorming tool that shows the connections between ideas.

14. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Assigns scores to weighted criteria for each project under consideration.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Prevention and appraisal costs are balanced against internal and external failure.
X-bar-bar

15. What is a histogram?
Prevention - appraisal - internal failure - external failure.
10 if Almost impossible to detect
Variable.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

16. What is Type 1 Error?
5%
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
Observed variation in response is caused by the input
Concluding there has been an effect/change when there has not.

17. How are LQL and AQL determined in an acceptance sampling plan?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Through producer/consumer negotiation.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

18. Taguchi's experimental designs are of this type.
The number of standard deviations some value is from the mean.
50%
Critical to quality.
Fractional factorial designs (orthogonal arrays)

19. If you can only collect categorical data - what type of SPC charting can you do?
Variable.
= 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
Attribute.
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

20. What is the role of a master black belt?
Attribute
No -- if it is not the same - it can only be worse!
Fractional factorial designs (orthogonal arrays)
To mentor/coach (and sometimes train) black belts.

21. Process check sheets
No -- only if the process is also capable.
To manage the Six Sigma project.
Used to create frequency distribution tally sheets
Different types of defects are listed (used for Pareto chart)

22. F value
Initiated before or at design concept finalization
Fewer good units to sell - increased variable cost/unit.
Method developed by Ishikawa to graphically display the causes of any given problem
F_alpha - df(tr) - df (error)

23. What is the center line of an X-bar chart?
Lean is waste reduction - Six Sigma is variation reduction.
X-bar-bar
Critical to quality.
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

24. What is a CAVE man?
Someone who is consistently against virtually everything.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Pleasing to the senses.
No -- only if the process is also capable.

25. What are two other names for an Ishikawa diagram?
Stratify a particular defect type according to logical criteria
To manage the Six Sigma project.
Fishbone - cause-and-effect diagram.
Prevention and appraisal costs are balanced against internal and external failure.

26. Affinity Diagrams
No -- the variation also has to be random and "expected."
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
Before production starts
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

27. What is muda
Waste.
Observed variation in response is caused by the input
Sampling for SPC is done real time.
To obtain a certain desirable outcome from the process

28. The data points on an SPC p-chart of defective percent plot below the mean. Is this good or bad?

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29. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Pleasing to the senses.
The US national quality award.
No -- the variation also has to be random and "expected."
Is what induces the failure

30. Complete this quality phrase: 'Fix the process - not the _____.'
Blame.
Is the consequence of the failure.
To do a capability study for a non-centered process.
Brand image.

31. How does Juran define quality?
Mistake-proofing.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Fitness for use.
50%

32. What is a dashboard?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A tool that shows performance along key dimensions all at once.
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
Used to create frequency distribution tally sheets

33. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
Prevention and appraisal costs are balanced against internal and external failure.
F_alpha - df(tr) - df (error)
QFD

34. In the Service Quality Gap Model - what is Gap 1?
The gap between what management thinks customers want and what customers really want.
Variable.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Lean (or JIT).

35. FMEA
It looks to minimize the probability of a failure - or to minimize its effects
To monitor a process when measurement by variables is used.
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
Is what induces the failure

36. What does the abbreviation LCL stand for?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Lean (or JIT).
Lower control limit.
To monitor a process when measurement by variables is used.

37. What happens to control limits on an SPC chart when sample size is increased?
The ratio of outputs to inputs; 1-scrap.
Attribute
They move closer to the center line.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

38. Who is a process owner?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
No -- only if the process is also capable.
The manager in charge of a process being improved in a Six Sigma project.

39. Define product reliability.
Blame.
Mean time to failure.
No -- only if the process is also capable.
Fewer good units to sell - increased variable cost/unit.

40. What is an affinity diagram?
10 if Almost impossible to detect
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
100%
A brainstorming tool that shows the connections between ideas.

41. The Test Statistic (TS)
Workers - machines - materials.
Inventory = throughput x flow time.
Used to create frequency distribution tally sheets
A random variable that summarizes the information from the sample(s).

42. Design of Experiments (DOE) approach
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
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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
Kaoru Ishikawa.

43. Manual Test for Nomality
Define - measure - analyze - improve - control.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Controlling quality at the source.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

44. What does SIPOC stand for?
=sqrt(Σ(x-x-bar)^2)/(n-1))
Taguchi
Supplier - input - process - output - customer.
F_alpha - df(tr) - df (error)

45. List Garvin's eight dimensions of product quality.
= yij - y(bar)i --> value minus sum of that treatment (of row)
The manager in charge of a process being improved in a Six Sigma project.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
A brainstorming tool that shows the connections between ideas.

46. What is Type II Error?
Concluding there has not been an effect/change when there has.
Lean is waste reduction - Six Sigma is variation reduction.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The degree to which a product meets pre-established standards.

47. When is Cpk used?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Before production starts
Hold all input variables constant except one. Observe the response as you vary the single input.
To do a capability study for a non-centered process.

48. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
To be a member of a Six Sigma project team.
Lower skill requirements - faster - less chance for error.
Define - measure - analyze - design - verify.
Supplier - input - process - output - customer.

49. 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?
The gap between what customers expect and the service they receive.
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
False - because each machine will have different natural tolerances.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

50. Define durability.
Mean time to replacement.
Represents the behavior of a process
A brainstorming tool that shows the connections between ideas.
Lean is waste reduction - Six Sigma is variation reduction.