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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. Does it ever make sense to accept a job when a process is incapable?
No -- if it is not the same - it can only be worse!
The gap between what management thinks customers want and what customers really want.
False - because each machine will have different natural tolerances.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

2. What type of risk is associated with Type 1 Error?
Producer risk.
Lean is waste reduction - Six Sigma is variation reduction.
The US national quality award.
Causes that lead to a particular effect.

3. What is the formula for the standard deviation of a proportion?
A diagram that shows the relationships between activities in a project network.
p-bar - the long-run percent defective.
The gap between what customers expect and the service they receive.
=sqrt((p*(1-p)/n)

4. Taguchi's experimental designs are of this type.
Is what induces the failure
Fractional factorial designs (orthogonal arrays)
The secondary characteristics of a product; "bells and whistles."
Define - measure - analyze - design - verify.

5. What is a histogram?
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
p-bar - the long-run percent defective.
To monitor a process when measurement by variables is used.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

6. In a regression - what does R-square tell you?
Because the mean and standard deviation are independent of each other.
Pleasing to the senses.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
To monitor a process when measurement by attribute is used.

7. What is Type 1 Error?
Fractional factorial designs (orthogonal arrays)
Concluding there has been an effect/change when there has not.
Speed - courtesy - competence - and ease of repair.
Stratify a particular defect type according to logical criteria

8. What are the four categories of costs in Juran's framework?
Prevention - appraisal - internal failure - external failure.
Represents the behavior of a process
Used to create frequency distribution tally sheets
Consumer risk.

9. What graphical tool is used to show the relationship between two numerical variables?
The US national quality award.
Studying firms with the best performance in a particular area.
False - because each machine will have different natural tolerances.
A scatterplot.

10. Design of Experiments (DOE) approach
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Organize ideas into meaningful categories by recognizing their underlying similarity
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Actual drawings - layouts - maps - etc which show where a defect occurs

11. 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
The gap between what management thinks customers want and what customers really want.
Waste.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

12. If a Cp shows that a process is not capable - should you calculate Cpk?
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
No -- if it is not the same - it can only be worse!
Someone who is consistently against virtually everything.
Used to create frequency distribution tally sheets

13. What is a Pareto chart?
Supplier - input - process - output - customer.
Lean is waste reduction - Six Sigma is variation reduction.
p-bar - the long-run percent defective.
A descending order-sorted bar chart with a cumulative percentage line.

14. In the Service Quality Gap Model - what is Gap 2?
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 gap between what management thinks customers want and the process specifications.
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) Plot a Line chart of the data in time sequence 2) Draw a line at the median

15. What is the 5S model?
Shifts - Trends - Repeating patterns - Correlation with known events
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Before production starts
Attribute

16. Defect location check sheets
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
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 number of standard deviations some value is from the mean.
Actual drawings - layouts - maps - etc which show where a defect occurs

17. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
Concluding there has not been an effect/change when there has.
Mean time to failure.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

18. Define perceived quality (Garvin's framework).
The gap between what management thinks customers want and what customers really want.
Blame.
Brand image.
To obtain a certain desirable outcome from the process

19. List two appraisal costs.
Attribute.
To mentor/coach (and sometimes train) black belts.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
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).

20. Based on what principal can we use the normal distribution assumptions for SPC?
Blame.
10 for Hazardous without warning 1 for none
The number of standard deviations some value is from the mean.
Central Limit Theorem

21. When is Cpk used?
To do a capability study for a non-centered process.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
0.9^3 or 72.9%

22. 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
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
False - because each machine will have different natural tolerances.
Defects Per Million Opportunities

23. Define serviceability.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Speed - courtesy - competence - and ease of repair.
Mean time to failure.
0.9^3 or 72.9%

24. What is the role of a green belt?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
To be a member of a Six Sigma project team.
Lower skill requirements - faster - less chance for error.
Critical to quality.

25. Process check sheets
Used to create frequency distribution tally sheets
Failure Modes and Effects Analysis
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
=sqrt(Σ(x-x-bar)^2)/(n-1))

26. What is a Gage R&R?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
=sqrt(Σ(x-x-bar)^2)/(n-1))
The number of standard deviations some value is from the mean.
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).

27. 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?
False - because each machine will have different natural tolerances.
Studying firms with the best performance in a particular area.
Defects Per Million Opportunities
Variable.

28. Uses of regression - Control
68%
To obtain a certain desirable outcome from the process
Concluding there has been an effect/change when there has not.
Method developed by Ishikawa to graphically display the causes of any given problem

29. What type of risk is associated with Type II Error?
Consumer risk.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Concluding there has been an effect/change when there has not.
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.

30. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Conformance to specifications.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Critical to quality.
The primary operating characteristics of a product.

31. Presence of interaction effect
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The ability of a process to consistently meet customer specifications.
Variable.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

32. What is the center line of a p-chart?
p-bar - the long-run percent defective.
Blame.
A time series plot.
Fewer good units to sell - increased variable cost/unit.

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

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34. ANOVA

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35. What does a project prioritization matrix do?
To be a member of a Six Sigma project team.
Assigns scores to weighted criteria for each project under consideration.
Failure Modes and Effects Analysis
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

36. Define takt time.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
If the Response vs. Levels graph if the response lines are not parallel (crossing)
The target number of standard deviations from the mean for specifications.
The cycle time required to meet demand.

37. Risk Priority Number RPN
Because the mean and standard deviation are independent of each other.
Actual drawings - layouts - maps - etc which show where a defect occurs
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Taguchi

38. What does DMAIC stand for?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Define - measure - analyze - improve - control.
Is what induces the failure
Look for the assignable cause of non-random variation.

39. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Inventory = throughput x flow time.
Look for the assignable cause of non-random variation.

40. What does the abbreviation LCL stand for?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
99.73%
Define - measure - analyze - improve - control.
Lower control limit.

41. What does Crosby say about benchmarking?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
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
Mistake-proofing.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

42. FMEA
Reliability - Assurance - Responsiveness - Tangibles - Empathy
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:
Is the consequence of the failure.
It looks to minimize the probability of a failure - or to minimize its effects

43. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
No -- only if the process is also capable.
100%
Central Limit Theorem
p-bar - the long-run percent defective.

44. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
To do a capability study for a non-centered process.
Define - measure - analyze - design - verify.
Outside.
The manager in charge of a process being improved in a Six Sigma project.

45. TWO-DIMENTIONAL SCATTER PLOT
Critical to quality.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Not necessarily.
Prevention and appraisal costs are balanced against internal and external failure.

46. What is Little's Law?
Blame.
Speed - courtesy - competence - and ease of repair.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Inventory = throughput x flow time.

47. What is a Gantt chart?
Large enough to find two of the attribute - on average.
Shows the temporal flow of activities in a project network.
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
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

48. Regression Analysis
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Used to create frequency distribution tally sheets
Look for the assignable cause of non-random variation.

49. F value
F_alpha - df(tr) - df (error)
Central Limit Theorem
Not necessarily.
Scrap - rework - retest - downtime - yield losses - disposition costs.

50. Explain the difference between technical and functional service quality.
The cycle time required to meet demand.
Technical quality is the "what" of the service; functional quality is the "how."
A tool that shows performance along key dimensions all at once.
Represents the behavior of a process