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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. Process check sheets
Reliability - Assurance - Responsiveness - Tangibles - Empathy
The primary operating characteristics of a product.
Used to create frequency distribution tally sheets
Initiated before or at design concept finalization

2. List Garvin's eight dimensions of product quality.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
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).
If the Response vs. Levels graph if the response lines are not parallel (crossing)

3. What is Little's Law?
Inventory = throughput x flow time.
The manager in charge of a process being improved in a Six Sigma project.
Sampling for SPC is done real time.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

4. Define serviceability.
Used to create frequency distribution tally 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
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).
Speed - courtesy - competence - and ease of repair.

5. What percentage of a normal distribution lies above the mean?
A scatterplot.
50%
Attribute.
Variable.

6. What are the four categories of costs in Juran's framework?
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).
Upper control limit.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Prevention - appraisal - internal failure - external failure.

7. For what is a p-chart used?
100%
Blame.
To monitor a process when measurement by attribute is used.
No -- only if the process is also capable.

8. What is the formula for the standard deviation of a proportion?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Define - measure - analyze - improve - control.
=sqrt((p*(1-p)/n)
To do a capability study for a non-centered process.

9. Who is a process owner?
Financial - customer - internal process - innovation and learning.
Fitness for use.
The manager in charge of a process being improved in a Six Sigma project.
Waste.

10. What is FMEA?
A tool that shows the physical flows through a space.
Failure Modes and Effects Analysis
The gap between specifications and how service is performed.
Conformance to specifications.

11. F value
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
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
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
F_alpha - df(tr) - df (error)

12. If you can only collect categorical data - what type of SPC charting can you do?
Workers - machines - materials.
Producer risk.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Attribute.

13. What is the role of a master black belt?
Inventory = throughput x flow time.
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).
QFD
To mentor/coach (and sometimes train) black belts.

14. When is Cpk used?
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
Brand image.
To do a capability study for a non-centered process.
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

15. What are the 5 Ss?
Studying firms with the best performance in a particular area.
Sort - Set in Order - Shine - Standardize - Sustain
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

16. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
Organize ideas into meaningful categories by recognizing their underlying similarity
A time series plot.
The ratio of outputs to inputs; 1-scrap.

17. Define takt time.
QFD
To monitor a process when measurement by variables is used.
The cycle time required to meet demand.
Large enough to find two of the attribute - on average.

18. Pareto Analysis
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The degree to which a product meets pre-established standards.
No -- if it is not the same - it can only be worse!
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

19. Definition of Interaction
p-bar - the long-run percent defective.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
A tool that shows performance along key dimensions all at once.
Assigns scores to weighted criteria for each project under consideration.

20. What is CTQ?
Pleasing to the senses.
Critical to quality.
Define - measure - analyze - design - verify.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

21. Does it ever make sense to accept a job when a process is incapable?
Different types of defects are listed (used for Pareto chart)
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
= 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

22. Complete this quality phrase: 'Fix the process - not the _____.'
68%
To manage the Six Sigma project.
Blame.
Failure Modes and Effects Analysis

23. What is the difference between Lean and Six Sigma?
Lean is waste reduction - Six Sigma is variation reduction.
Look for the assignable cause of non-random variation.
Through producer/consumer negotiation.
To mentor/coach (and sometimes train) black belts.

24. What do you do when a process is out of control?
Look for the assignable cause of non-random variation.
Mean time to replacement.
Method developed by Ishikawa to graphically display the causes of any given problem
Define - measure - analyze - improve - control.

25. What is a Gage R&R?
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).
To monitor a process when measurement by variables is used.
Defects Per Million Opportunities
Look for the assignable cause of non-random variation.

26. Affinity Diagrams
Can't tell without a Range chart.
Organize ideas into meaningful categories by recognizing their underlying similarity
Critical to quality.
Fishbone - cause-and-effect diagram.

27. 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
Someone who is consistently against virtually everything.
Lower control limit.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

28. What is a Gantt chart?
Someone who is consistently against virtually everything.
p-bar - the long-run percent defective.
Shows the temporal flow of activities in a project network.
Controlling quality at the source.

29. Uses of regression
Prevention and appraisal costs are balanced against internal and external failure.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The manager in charge of a process being improved in a Six Sigma project.
A tool that shows the physical flows through a space.

30. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
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.
Speed - courtesy - competence - and ease of repair.

31. Who developed the fishbone diagram?
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 Japanese national quality award.
Kaoru Ishikawa.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

32. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Before production starts
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Attribute

33. Define features.
No -- only if the process is also capable.
A random variable that summarizes the information from the sample(s).
The secondary characteristics of a product; "bells and whistles."
Defects Per Million Opportunities

34. DOE
Actual drawings - layouts - maps - etc which show where a defect occurs
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Look for the assignable cause of non-random variation.
Concluding there has been an effect/change when there has not.

35. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Someone who is consistently against virtually everything.
68%
To obtain a certain desirable outcome from the process
Large enough to find two of the attribute - on average.

36. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
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
Prevention and appraisal costs are balanced against internal and external failure.
The gap between what management thinks customers want and the process specifications.

37. Define benchmarking.
Shows the temporal flow of activities in a project network.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Studying firms with the best performance in a particular area.

38. What does the abbreviation LCL stand for?
Organize ideas into meaningful categories by recognizing their underlying similarity
Lower control limit.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Pleasing to the senses.

39. Which quality guru developed the concept of loss to society?
To mentor/coach (and sometimes train) black belts.
Taguchi
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Deming.

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

41. What is an affinity diagram?
A brainstorming tool that shows the connections between ideas.
Lower skill requirements - faster - less chance for error.
99.73%
The degree to which a product meets pre-established standards.

42. What is a Pareto chart?
Attribute
A descending order-sorted bar chart with a cumulative percentage line.
The House of Quality.
The secondary characteristics of a product; "bells and whistles."

43. Test for Independence
They move closer to the center line.
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
Concluding there has been an effect/change when there has not.
Financial - customer - internal process - innovation and learning.

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

45. One factor at a time (OFAT)
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).
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
No -- if it is not the same - it can only be worse!
Observed variation in response is caused by the input

46. FMEA
Assigns scores to weighted criteria for each project under consideration.
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
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
Scrap - rework - retest - downtime - yield losses - disposition costs.

47. In a regression - what does R-square tell you?
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 amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Scrap - rework - retest - downtime - yield losses - disposition costs.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

48. Define aesthetic quality.
Consumer risk.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Pleasing to the senses.
Is what induces the failure

49. What is Type II Error?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
No -- if it is not the same - it can only be worse!
Concluding there has not been an effect/change when there has.
Assigns scores to weighted criteria for each project under consideration.

50. Non-random patterns (Run Charts)
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Is the way in which the failure is manifested.
Sort - Set in Order - Shine - Standardize - Sustain
Shifts - Trends - Repeating patterns - Correlation with known events