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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 performance quality.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
5%
Speed - courtesy - competence - and ease of repair.
The primary operating characteristics of a product.

2. DFMEA
Initiated before or at design concept finalization
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
The gap between what is promised and what is delivered.
To mentor/coach (and sometimes train) black belts.

3. What are the four perspectives of the Balanced Scorecard?
The ability of a process to consistently meet customer specifications.
Financial - customer - internal process - innovation and learning.
A scatterplot.
Attribute

4. Residual(eij)
Rapid improvement process.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Taguchi
Shifts - Trends - Repeating patterns - Correlation with known events

5. One factor at a time (OFAT)
Linearity - normality - homoscedasticity - independence.
Observed variation in response is caused by the input
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 number of standard deviations some value is from the mean.

6. Define features.
The secondary characteristics of a product; "bells and whistles."
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
A brainstorming tool that shows the connections between ideas.
Fewer good units to sell - increased variable cost/unit.

7. What is the Deming Prize?
The gap between what customers expect and the service they receive.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Speed - courtesy - competence - and ease of repair.
The Japanese national quality award.

8. What quality guru emphasizes management as a system?
No -- only if the process is also capable.
Consumer risk.
Deming.
3.4 (assuming 1.5 sigma shift in the mean)

9. In the Service Quality Gap Model - what is Gap 4?
Deming.
The gap between what is promised and what is delivered.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Through producer/consumer negotiation.

10. What is Type II Error?
The gap between what management thinks customers want and what customers really want.
The cycle time required to meet demand.
Defects Per Million Opportunities
Concluding there has not been an effect/change when there has.

11. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
95%
A random variable that summarizes the information from the sample(s).
Mean time to replacement.

12. Who developed the fishbone diagram?
The gap between what management thinks customers want and the process specifications.
Deming.
It's good -- but it's still out of control!
Kaoru Ishikawa.

13. Define durability.
Mean time to replacement.
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:
Pleasing to the senses.
A brainstorming tool that shows the connections between ideas.

14. How are LQL and AQL determined in an acceptance sampling plan?
X-bar-bar
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Through producer/consumer negotiation.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

15. Regression
Shifts - Trends - Repeating patterns - Correlation with known events
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
Stratify a particular defect type according to logical criteria
Represents the behavior of a process

16. Define serviceability.
Can't tell without a Range chart.
Pleasing to the senses.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Speed - courtesy - competence - and ease of repair.

17. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
10 for Hazardous without warning 1 for none
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
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

18. For what is a p-chart used?
Technical quality is the "what" of the service; functional quality is the "how."
To monitor a process when measurement by attribute is used.
10 if Almost impossible to detect
Define - measure - analyze - improve - control.

19. Test for Independence
To manage the Six Sigma project.
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
A scatterplot.
To monitor a process when measurement by variables is used.

20. What is Jidoka?
The gap between what is promised and what is delivered.
Used to create frequency distribution tally sheets
Controlling quality at the source.
A descending order-sorted bar chart with a cumulative percentage line.

21. What is the 5S model?
Deming.
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
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
The gap between what management thinks customers want and what customers really want.

22. What is Kaizen?
Producer risk.
The ratio of outputs to inputs; 1-scrap.
Kaoru Ishikawa.
Rapid improvement process.

23. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
The degree to which a product meets pre-established standards.
5%
To do a capability study for a non-centered process.
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).

24. What are the Five Dimensions of Service Quality?
Variable.
A brainstorming tool that shows the connections between ideas.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Walter A. Shewhart

25. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
The number of standard deviations some value is from the mean.
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).
Kaoru Ishikawa.
Variable.

26. What is the center line of an X-bar chart?
Sort - Set in Order - Shine - Standardize - Sustain
Through producer/consumer negotiation.
X-bar-bar
Lower control limit.

27. What is the role of a green belt?
To be a member of a Six Sigma project team.
Large enough to find two of the attribute - on average.
Before production starts
50%

28. Taguchi's experimental designs are of this type.
Not necessarily.
Fractional factorial designs (orthogonal arrays)
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

29. With Six Sigma capability - how many defects per million opportunities would you see?
Brand image.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
100%
3.4 (assuming 1.5 sigma shift in the mean)

30. What is a Pareto chart?
A descending order-sorted bar chart with a cumulative percentage line.
Supplier - input - process - output - customer.
To monitor a process when measurement by variables is used.
X-bar-bar

31. In the Service Quality Gap Model - what is Gap 3?
Large enough to find two of the attribute - on average.
The gap between what management thinks customers want and the process specifications.
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 gap between specifications and how service is performed.

32. Disadvantages of DOE

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33. Defect check sheets
Different types of defects are listed (used for Pareto chart)
Deming.
Actual drawings - layouts - maps - etc which show where a defect occurs
Look for the assignable cause of non-random variation.

34. What happens to control limits on an SPC chart when sample size is increased?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
3.4 (assuming 1.5 sigma shift in the mean)
Attribute.
They move closer to the center line.

35. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
Variable.
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).
The number of standard deviations some value is from the mean.

36. Uses of regression
Attribute
Define - measure - analyze - design - verify.
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
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

37. Define yield.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The ratio of outputs to inputs; 1-scrap.
Sort - Set in Order - Shine - Standardize - Sustain
Failure Modes and Effects Analysis

38. Advantages of DOE
To obtain a certain desirable outcome from the process
Taguchi
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
Is the way in which the failure is manifested.

39. What does Crosby say about benchmarking?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Used to create frequency distribution tally sheets
Fewer good units to sell - increased variable cost/unit.
Mistake-proofing.

40. What is a Gage R&R?
A tool that shows where there is waste in a process.
3.4 (assuming 1.5 sigma shift in the mean)
Deming.
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).

41. What is a CAVE man?
Someone who is consistently against virtually everything.
Lower skill requirements - faster - less chance for error.
Define - measure - analyze - design - verify.
Scrap - rework - retest - downtime - yield losses - disposition costs.

42. What are two other names for an Ishikawa diagram?
They move closer to the center line.
Represents the behavior of a process
Financial - customer - internal process - innovation and learning.
Fishbone - cause-and-effect diagram.

43. What quality tool formally incorporates the voice of the customer?
QFD
Outside.
Fewer good units to sell - increased variable cost/unit.
Organize ideas into meaningful categories by recognizing their underlying similarity

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

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45. What is the Baldrige Award?
95%
Hold all input variables constant except one. Observe the response as you vary the single input.
The US national quality award.
=sqrt(Σ(x-x-bar)^2)/(n-1))

46. What is Value Stream Mapping?
To monitor a process when measurement by variables is used.
Mean time to replacement.
A tool that shows where there is waste in a process.
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

47. List Garvin's eight dimensions of product quality.
Define - measure - analyze - design - verify.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
= 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
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

48. What is FMEA?
To be a member of a Six Sigma project team.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Not necessarily.
Failure Modes and Effects Analysis

49. Which quality guru developed the concept of loss to society?
Taguchi
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The manager in charge of a process being improved in a Six Sigma project.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

50. What is process capability?
The ability of a process to consistently meet customer specifications.
The degree to which a product meets pre-established standards.
The gap between what management thinks customers want and what customers really want.
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