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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. Define aesthetic quality.
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
3.4 (assuming 1.5 sigma shift in the mean)
Pleasing to the senses.
Causes that lead to a particular effect.

2. Who is a process owner?
To mentor/coach (and sometimes train) black belts.
Variable.
The manager in charge of a process being improved in a Six Sigma project.
Attribute

3. What are the four categories of costs in Juran's framework?
The target number of standard deviations from the mean for specifications.
Walter A. Shewhart
Prevention - appraisal - internal failure - external failure.
Fitness for use.

4. What are the three main categories of assignable cause?
Workers - machines - materials.
Prevention - appraisal - internal failure - external failure.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
100%

5. Complete this quality phrase: 'Fix the process - not the _____.'
Blame.
The primary operating characteristics of a product.
To obtain a certain desirable outcome from the process
To monitor a process when measurement by variables is used.

6. Risk Priority Number RPN
5%
Supplier - input - process - output - customer.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
F_alpha - df(tr) - df (error)

7. In a regression - what does the coefficient of the intercept tell you
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
X-bar-bar
What the value of the dependent variable is when the independent variable is zero.
Fitness for use.

8. What is process capability?
The ability of a process to consistently meet customer specifications.
The ratio of outputs to inputs; 1-scrap.
Speed - courtesy - competence - and ease of repair.
A brainstorming tool that shows the connections between ideas.

9. What does DMAIC stand for?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
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
Shows the temporal flow of activities in a project network.
Define - measure - analyze - improve - control.

10. If a three-stage process has 90% yields at each stage - what is the overall yield?
Through producer/consumer negotiation.
0.9^3 or 72.9%
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.
Lower control limit.

11. List two components of external failure.
Sort - Set in Order - Shine - Standardize - Sustain
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

12. Test for Independence
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
Defects Per Million Opportunities
Can't tell without a Range chart.
To monitor a process when measurement by attribute is used.

13. PFMEA
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
99.73%
Technical quality is the "what" of the service; functional quality is the "how."
Before production starts

14. What is Type II Error?
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).
Concluding there has not been an effect/change when there has.
Failure Modes and Effects Analysis
To do a capability study for a non-centered process.

15. Stratified defect check sheets
Look for the assignable cause of non-random variation.
Causes that lead to a particular effect.
Stratify a particular defect type according to logical criteria
To do a capability study for a non-centered process.

16. List two components of prevention cost.
The degree to which a product meets pre-established standards.
The ability of a process to consistently meet customer specifications.
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.

17. Define performance quality.
Lower control limit.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
The primary operating characteristics of a product.
The gap between what customers expect and the service they receive.

18. What is the role of a green belt?
Speed - courtesy - competence - and ease of repair.
Prevention and appraisal costs are balanced against internal and external failure.
Defects Per Million Opportunities
To be a member of a Six Sigma project team.

19. In a regression - what does the standard error of the estimate tell you?
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
Pleasing to the senses.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Scrap - rework - retest - downtime - yield losses - disposition costs.

20. Regression
A time series plot.
Supplier - input - process - output - customer.
The Japanese national quality award.
Represents the behavior of a process

21. What is the center line of a p-chart?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
p-bar - the long-run percent defective.
Inventory = throughput x flow time.

22. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
= yij - y(bar)i --> value minus sum of that treatment (of row)
Lean (or JIT).
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Financial - customer - internal process - innovation and learning.

23. In the Service Quality Gap Model - what is Gap 4?
Fitness for use.
F_alpha - df(tr) - df (error)
The gap between what is promised and what is delivered.
Failure Modes and Effects Analysis

24. What are the 5 Ss?
A tool that shows where there is waste in a process.
A tool that shows performance along key dimensions all at once.
Sort - Set in Order - Shine - Standardize - Sustain
Is what induces the failure

25. Simple Regression Analysis (one factor regression model)
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Organize ideas into meaningful categories by recognizing their underlying similarity
The US national quality award.
= 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

26. Definition of Interaction
Lower skill requirements - faster - less chance for error.
The secondary characteristics of a product; "bells and whistles."
Technical quality is the "what" of the service; functional quality is the "how."
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

27. Defect location check sheets
To monitor a process when measurement by attribute is used.
Attribute
Actual drawings - layouts - maps - etc which show where a defect occurs
Different types of defects are listed (used for Pareto chart)

28. Failure effect
5%
3.4 (assuming 1.5 sigma shift in the mean)
Inventory = throughput x flow time.
Is the consequence of the failure.

29. Define perceived quality (Garvin's framework).
A tool that shows performance along key dimensions all at once.
10 for Hazardous without warning 1 for none
Brand image.
To be a member of a Six Sigma project team.

30. Disadvantages of DOE

31. 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).
The House of Quality.
Actual drawings - layouts - maps - etc which show where a defect occurs
Technical quality is the "what" of the service; functional quality is the "how."

32. Affinity Diagrams
A tool that shows the physical flows through a space.
A diagram that shows the relationships between activities in a project network.
Not necessarily.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

33. Which quality guru developed the concept of loss to society?
The gap between what management thinks customers want and what customers really want.
Upper control limit.
To monitor a process when measurement by attribute is used.
Taguchi

34. Daniel Test
A tool that shows where there is waste in a process.
Initiated before or at design concept finalization
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:
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

35. Taguchi's experimental designs are of this type.
Large enough to find two of the attribute - on average.
Fractional factorial designs (orthogonal arrays)
95%
What the value of the dependent variable is when the independent variable is zero.

36. A process is operating "in control." Does this mean the customer's requirements are met?
Lean is waste reduction - Six Sigma is variation reduction.
Large enough to find two of the attribute - on average.
X-bar-bar
No -- only if the process is also capable.

37. What graphical tool is used to show the relationship between two numerical variables?
A scatterplot.
100%
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
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

38. If you can only collect categorical data - what type of SPC charting can you do?
Technical quality is the "what" of the service; functional quality is the "how."
A time series plot.
Workers - machines - materials.
Attribute.

39. What is the role of a black belt?
To manage the Six Sigma project.
Look for the assignable cause of non-random variation.
Sort - Set in Order - Shine - Standardize - Sustain
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

40. What is the center line of an X-bar chart?
=sqrt(Σ(x-x-bar)^2)/(n-1))
X-bar-bar
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
5%

41. What is Type 1 Error?
A tool that shows performance along key dimensions all at once.
Observed variation in response is caused by the input
Concluding there has been an effect/change when there has not.
Kaoru Ishikawa.

42. Non-random patterns (Run Charts)
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Shifts - Trends - Repeating patterns - Correlation with known events
A tool that shows the physical flows through a space.

43. For what is a p-chart used?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
To do a capability study for a non-centered process.
Producer risk.
To monitor a process when measurement by attribute is used.

44. What happens to control limits on an SPC chart when sample size is increased?
Failure Modes and Effects Analysis
The gap between what management thinks customers want and the process specifications.
The Japanese national quality award.
They move closer to the center line.

45. How are LQL and AQL determined in an acceptance sampling plan?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
No -- if it is not the same - it can only be worse!
Through producer/consumer negotiation.
Mean time to replacement.

46. What size should samples be for attribute SPC?
Supplier - input - process - output - customer.
A scatterplot.
Large enough to find two of the attribute - on average.
=sqrt(Σ(x-x-bar)^2)/(n-1))

47. What is muda
Critical to quality.
Waste.
Define - measure - analyze - design - verify.
Failure Modes and Effects Analysis

48. What quality guru emphasizes management as a system?
Deming.
Linearity - normality - homoscedasticity - independence.
Walter A. Shewhart
Waste.

49. The Test Statistic (TS)
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
A random variable that summarizes the information from the sample(s).
Taguchi
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

50. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Supplier - input - process - output - customer.
Variable.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
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: