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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. Pareto Analysis
Shifts - Trends - Repeating patterns - Correlation with known events
Walter A. Shewhart
Blame.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

2. What is written on the "spines" of a fishbone diagram?
Variable.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Causes that lead to a particular effect.
= 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

3. Risk Priority Number RPN
To mentor/coach (and sometimes train) black belts.
Assigns scores to weighted criteria for each project under consideration.
A random variable that summarizes the information from the sample(s).
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

4. What is Value Stream Mapping?
False - because each machine will have different natural tolerances.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Fitness for use.
A tool that shows where there is waste in a process.

5. If a Cp shows that a process is not capable - should you calculate Cpk?
Fewer good units to sell - increased variable cost/unit.
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!
Shifts - Trends - Repeating patterns - Correlation with known events

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

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7. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Lower control limit.
Lean is waste reduction - Six Sigma is variation reduction.
Outside.
A scatterplot.

8. What is the Deming Prize?
Mean time to failure.
Financial - customer - internal process - innovation and learning.
The Japanese national quality award.
Waste.

9. In the Service Quality Gap Model - what is Gap 3?
The gap between specifications and how service is performed.
Can't tell without a Range chart.
The US national quality award.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

10. Disadvantages of DOE

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11. Define durability.
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.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Attribute.
Mean time to replacement.

12. Define yield.
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:
The House of Quality.
The ratio of outputs to inputs; 1-scrap.
Producer risk.

13. A process is operating "in control." Does this mean the customer's requirements are met?
X-bar-bar
Fishbone - cause-and-effect diagram.
No -- only if the process is also capable.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

14. What is poka yoke?
Controlling quality at the source.
Mistake-proofing.
Critical to quality.
= 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

15. What is process capability?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A random variable that summarizes the information from the sample(s).
Sampling for SPC is done real time.
The ability of a process to consistently meet customer specifications.

16. 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?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Consumer risk.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
False - because each machine will have different natural tolerances.

17. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
To do a capability study for a non-centered process.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Attribute

18. What type of risk is associated with Type II Error?
They move closer to the center line.
Consumer risk.
Mistake-proofing.
Define - measure - analyze - improve - control.

19. Creating a Run Chart
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Pleasing to the senses.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
The gap between what management thinks customers want and what customers really want.

20. Name the structure associated with Quality Function Deployment.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Hold all input variables constant except one. Observe the response as you vary the single input.
The primary operating characteristics of a product.
The House of Quality.

21. Your production process meets customer specifications. Is your process in control?
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.
Not necessarily.
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).
Look for the assignable cause of non-random variation.

22. FMEA
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
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Is the consequence of the failure.

23. What happens to control limits on an SPC chart when sample size is increased?
The cycle time required to meet demand.
To monitor a process when measurement by attribute is used.
Sampling for SPC is done real time.
They move closer to the center line.

24. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Lower skill requirements - faster - less chance for error.
The gap between what is promised and what is delivered.
It's good -- but it's still out of control!
To monitor a process when measurement by variables is used.

25. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Pleasing to the senses.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Lean (or JIT).
p-bar - the long-run percent defective.

26. In the Service Quality Gap Model - what is Gap 4?
99.73%
Before production starts
To do a capability study for a non-centered process.
The gap between what is promised and what is delivered.

27. Advantages of DOE
The manager in charge of a process being improved in a Six Sigma project.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Scrap - rework - retest - downtime - yield losses - disposition costs.
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

28. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Initiated before or at design concept finalization
Stratify a particular defect type according to logical criteria
Sampling for SPC is done real time.
Pleasing to the senses.

29. One factor at a time (OFAT)
Waste.
Hold all input variables constant except one. Observe the response as you vary the single 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
10 for Hazardous without warning 1 for none

30. In Juran's Cost of Quality model - which categories of costs balance which other categories?
The gap between what is promised and what is delivered.
Shows the temporal flow of activities in a project network.
Prevention and appraisal costs are balanced against internal and external failure.
99.73%

31. What type of risk is associated with Type 1 Error?
0.9^3 or 72.9%
Walter A. Shewhart
A tool that shows where there is waste in a process.
Producer risk.

32. Failure cause
Is what induces the failure
10 if Almost impossible to detect
A tool that shows performance along key dimensions all at once.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

33. Stratified defect check sheets
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
Stratify a particular defect type according to logical criteria
QFD
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

34. If you can only collect categorical data - what type of SPC charting can you do?
Attribute.
=sqrt(Σ(x-x-bar)^2)/(n-1))
F_alpha - df(tr) - df (error)
Reliability - Assurance - Responsiveness - Tangibles - Empathy

35. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
Organize ideas into meaningful categories by recognizing their underlying similarity
Variable.
Is the way in which the failure is manifested.

36. What quality tool formally incorporates the voice of the customer?
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
QFD
They move closer to the center line.

37. What does Crosby say about benchmarking?
The gap between what is promised and what is delivered.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

38. In a regression - what does the standard error of the estimate tell you?
Central Limit Theorem
Rapid improvement process.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
To do a capability study for a non-centered process.

39. Define aesthetic quality.
What the value of the dependent variable is when the independent variable is zero.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Pleasing to the senses.

40. Uses of regression - Control
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
To obtain a certain desirable outcome from the process
Not necessarily.
Actual drawings - layouts - maps - etc which show where a defect occurs

41. How are LQL and AQL determined in an acceptance sampling plan?
Through producer/consumer negotiation.
Someone who is consistently against virtually everything.
=sqrt(Σ(x-x-bar)^2)/(n-1))
95%

42. 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
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
What the value of the dependent variable is when the independent variable is zero.
3.4 (assuming 1.5 sigma shift in the mean)

43. Design of Experiments (DOE) approach
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The gap between what customers expect and the service they receive.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

44. PFMEA
Before production starts
A tool that shows where there is waste in a process.
Prevention and appraisal costs are balanced against internal and external failure.
A scatterplot.

45. For what is an x-bar chart used?
The US national quality award.
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:
To monitor a process when measurement by variables is used.
Conformance to specifications.

46. Define serviceability.
Speed - courtesy - competence - and ease of repair.
To obtain a certain desirable outcome from the process
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
10 for Hazardous without warning 1 for none

47. Who first studied randomness in industrial processes
Walter A. Shewhart
To manage the Six Sigma project.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Represents the behavior of a process

48. Regression
Linearity - normality - homoscedasticity - independence.
Scrap - rework - retest - downtime - yield losses - disposition costs.
The gap between what customers expect and the service they receive.
Represents the behavior of a process

49. Who developed the fishbone diagram?
Brand image.
Kaoru Ishikawa.
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 manager in charge of a process being improved in a Six Sigma project.

50. Does it ever make sense to accept a job when a process is incapable?
To monitor a process when measurement by attribute is used.
The House of Quality.
X-bar-bar
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.