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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. Manual Test for Nomality
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)
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

2. What is the difference between the way sampling is done for SPC and for acceptance sampling?
The secondary characteristics of a product; "bells and whistles."
To do a capability study for a non-centered process.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Sampling for SPC is done real time.

3. What is a Gantt chart?
Shows the temporal flow of activities in a project network.
Concluding there has not been an effect/change when there has.
A brainstorming tool that shows the connections between ideas.
False - because each machine will have different natural tolerances.

4. Pareto Analysis
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Fewer good units to sell - increased variable cost/unit.
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 process of ranking opportunities to determine which of many potential opportunities should be pursued first.

5. Creating a Run Chart
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
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
The primary operating characteristics of a product.

6. DOE
Reliability - Assurance - Responsiveness - Tangibles - Empathy
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Shows the temporal flow of activities in a project network.
Method developed by Ishikawa to graphically display the causes of any given problem

7. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
The Japanese national quality award.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

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

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9. For what is a p-chart used?
Attribute
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
To monitor a process when measurement by attribute is used.
The ratio of outputs to inputs; 1-scrap.

10. What type of risk is associated with Type 1 Error?
Initiated before or at design concept finalization
The gap between specifications and how service is performed.
Producer risk.
Inventory = throughput x flow time.

11. One factor at a time (OFAT)
Not necessarily.
To do a capability study for a non-centered process.
Defects Per Million Opportunities
Observed variation in response is caused by the input

12. F value
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
Initiated before or at design concept finalization
F_alpha - df(tr) - df (error)
Shifts - Trends - Repeating patterns - Correlation with known events

13. Regression
Represents the behavior of a process
Fractional factorial designs (orthogonal arrays)
The US national quality award.
Causes that lead to a particular effect.

14. What are the four perspectives of the Balanced Scorecard?
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.
Supplier - input - process - output - customer.
Fishbone - cause-and-effect diagram.

15. Explain the difference between technical and functional service quality.
Is the consequence of the failure.
Technical quality is the "what" of the service; functional quality is the "how."
A time series plot.
To mentor/coach (and sometimes train) black belts.

16. Advantages of DOE
To mentor/coach (and sometimes train) black belts.
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
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

17. What is a dashboard?
The gap between what management thinks customers want and what customers really want.
A tool that shows performance along key dimensions all at once.
Define - measure - analyze - improve - control.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

18. Defect location check sheets
Concluding there has not been an effect/change when there has.
Sampling for SPC is done real time.
Actual drawings - layouts - maps - etc which show where a defect occurs
Upper control limit.

19. What are the 5 Ss?
Sort - Set in Order - Shine - Standardize - Sustain
p-bar - the long-run percent defective.
=sqrt((p*(1-p)/n)
= yij - y(bar)i --> value minus sum of that treatment (of row)

20. When yields decrease - what are the two effects on contribution?
Is what induces the failure
Fewer good units to sell - increased variable cost/unit.
No -- if it is not the same - it can only be worse!
Pleasing to the senses.

21. Failure cause
Is what induces the failure
Central Limit Theorem
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Through producer/consumer negotiation.

22. Who developed the fishbone diagram?
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).
Failure Modes and Effects Analysis
Fractional factorial designs (orthogonal arrays)
Kaoru Ishikawa.

23. List two components of internal failure.
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).
Scrap - rework - retest - downtime - yield losses - disposition costs.
Initiated before or at design concept finalization
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

24. Name the structure associated with Quality Function Deployment.
The House of Quality.
Lower control limit.
False - because each machine will have different natural tolerances.
The secondary characteristics of a product; "bells and whistles."

25. What is process capability?
The ability of a process to consistently meet customer specifications.
An assertion or conjecture concerning one or more populations
Before production starts
Consumer risk.

26. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
A tool that shows the physical flows through a space.
Taguchi
3.4 (assuming 1.5 sigma shift in the mean)

27. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Shifts - Trends - Repeating patterns - Correlation with known events
Lean (or JIT).
The degree to which a product meets pre-established standards.
Mistake-proofing.

28. What is the formula for the standard deviation of a proportion?
Brand image.
Look for the assignable cause of non-random variation.
Scrap - rework - retest - downtime - yield losses - disposition costs.
=sqrt((p*(1-p)/n)

29. What does SIPOC stand for?
Initiated before or at design concept finalization
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Supplier - input - process - output - customer.
Technical quality is the "what" of the service; functional quality is the "how."

30. Residual
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
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.
Brand image.
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

31. PFMEA
Before production starts
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 cycle time required to meet demand.
Concluding there has been an effect/change when there has not.

32. What is the Deming Prize?
The Japanese national quality award.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
The ability of a process to consistently meet customer specifications.
A tool that shows the physical flows through a space.

33. What is the center line of an X-bar chart?
X-bar-bar
99.73%
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The secondary characteristics of a product; "bells and whistles."

34. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Deming.
The gap between what management thinks customers want and what customers really want.
Mean time to replacement.
No -- the variation also has to be random and "expected."

35. TWO-DIMENTIONAL SCATTER PLOT
Sort - Set in Order - Shine - Standardize - Sustain
The secondary characteristics of a product; "bells and whistles."
Variable.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

36. Risk Priority Number RPN
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Inventory = throughput x flow time.
A random variable that summarizes the information from the sample(s).
Attribute

37. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
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
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
68%
Financial - customer - internal process - innovation and learning.

38. What is an affinity diagram?
Outside.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
A brainstorming tool that shows the connections between ideas.

39. Failure effect
Define - measure - analyze - improve - control.
Is the consequence of the failure.
What the value of the dependent variable is when the independent variable is zero.
p-bar - the long-run percent defective.

40. Affinity Diagrams
Inventory = throughput x flow time.
A tool that shows where there is waste in a process.
Organize ideas into meaningful categories by recognizing their underlying similarity
Through producer/consumer negotiation.

41. What is Kaizen?
Different types of defects are listed (used for Pareto chart)
Rapid improvement process.
Actual drawings - layouts - maps - etc which show where a defect occurs
The Japanese national quality award.

42. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
X-bar-bar
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The primary operating characteristics of a product.

43. How does Juran define quality?
Fitness for use.
Causes that lead to a particular effect.
The secondary characteristics of a product; "bells and whistles."
The gap between specifications and how service is performed.

44. Complete this quality phrase: 'Fix the process - not the _____.'
Before production starts
Blame.
QFD
Defects Per Million Opportunities

45. You have been plotting sample means on an x-bar chart and all points indicate normal - expected variation. Is the process in control?

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46. Which quality guru developed the concept of loss to society?
Taguchi
F_alpha - df(tr) - df (error)
The gap between what customers expect and the service they receive.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

47. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Prevention - appraisal - internal failure - external failure.
Observed variation in response is caused by the input
Attribute
Lean is waste reduction - Six Sigma is variation reduction.

48. What is FMEA?
Concluding there has not been an effect/change when there has.
The manager in charge of a process being improved in a Six Sigma project.
Failure Modes and Effects Analysis
Observed variation in response is caused by the input

49. What percentage of a normal distribution lies above the mean?
50%
Blame.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
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).

50. Why do you need two control charts for variables SPC?
A diagram that shows the relationships between activities in a project network.
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
Because the mean and standard deviation are independent of each other.
Workers - machines - materials.