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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. How are LQL and AQL determined in an acceptance sampling plan?
Through producer/consumer negotiation.
To mentor/coach (and sometimes train) black belts.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
QFD

2. In a regression - what does the coefficient of the intercept tell you
What the value of the dependent variable is when the independent variable is zero.
Mean time to replacement.
The gap between what management thinks customers want and what customers really want.
The cycle time required to meet demand.

3. What is process capability?
The ability of a process to consistently meet customer specifications.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The Japanese national quality award.

4. Who is a process owner?
It's good -- but it's still out of control!
Technical quality is the "what" of the service; functional quality is the "how."
The manager in charge of a process being improved in a Six Sigma project.
Prevention - appraisal - internal failure - external failure.

5. What is FMEA?
Failure Modes and Effects Analysis
Represents the behavior of a process
3.4 (assuming 1.5 sigma shift in the mean)
50%

6. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Deming.
No -- the variation also has to be random and "expected."
= 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
99.73%

7. What does SIPOC stand for?
The gap between specifications and how service is performed.
Blame.
Supplier - input - process - output - customer.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

8. List two components of prevention cost.
Shows the temporal flow of activities in a project network.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
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
Inventory = throughput x flow time.

9. What does DMAIC stand for?
The House of Quality.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Define - measure - analyze - improve - control.
3.4 (assuming 1.5 sigma shift in the mean)

10. Define product reliability.
Shifts - Trends - Repeating patterns - Correlation with known events
Scrap - rework - retest - downtime - yield losses - disposition costs.
Mean time to failure.
Lower skill requirements - faster - less chance for error.

11. What is a Gantt chart?
Someone who is consistently against virtually everything.
Shows the temporal flow of activities in a project network.
The gap between specifications and how service is performed.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

12. Advantages of DOE
To monitor a process when measurement by variables is used.
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
Lean is waste reduction - Six Sigma is variation reduction.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

13. Define durability.
Look for the assignable cause of non-random variation.
Mean time to replacement.
= 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
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

14. FMEA
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
It looks to minimize the probability of a failure - or to minimize its effects
3.4 (assuming 1.5 sigma shift in the mean)
Is the consequence of the failure.

15. What is an affinity diagram?
A brainstorming tool that shows the connections between ideas.
No -- if it is not the same - it can only be worse!
Scrap - rework - retest - downtime - yield losses - disposition costs.
Attribute

16. What is the Deming Prize?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Waste.
The Japanese national quality award.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

17. What is written on the "spines" of a fishbone diagram?
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
Causes that lead to a particular effect.
QFD
Prevention - appraisal - internal failure - external failure.

18. Define yield.
The ratio of outputs to inputs; 1-scrap.
Taguchi
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.

19. Definition of Interaction
The ratio of outputs to inputs; 1-scrap.
Hold all input variables constant except one. Observe the response as you vary the single input.
Speed - courtesy - competence - and ease of repair.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

20. What is the 5S model?
Rapid improvement process.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
= 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
Before production starts

21. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Sampling for SPC is done real time.
A brainstorming tool that shows the connections between ideas.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Reliability - Assurance - Responsiveness - Tangibles - Empathy

22. List Garvin's eight dimensions of product quality.
Mean time to failure.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

23. In a regression - what does R-square tell you?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Different types of defects are listed (used for Pareto chart)
Is the way in which the failure is manifested.
The primary operating characteristics of a product.

24. What is the formula for standard deviation?
Large enough to find two of the attribute - on average.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Concluding there has not been an effect/change when there has.
Rapid improvement process.

25. In the Service Quality Gap Model - what is Gap 2?
Upper control limit.
The gap between specifications and how service is performed.
The gap between what management thinks customers want and the process specifications.
QFD

26. Daniel Test
Method developed by Ishikawa to graphically display the causes of any given problem
Upper control limit.
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:
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

27. What is poka yoke?
Before production starts
Workers - machines - materials.
To do a capability study for a non-centered process.
Mistake-proofing.

28. Presence of interaction effect
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Through producer/consumer negotiation.
Inventory = throughput x flow time.

29. One factor at a time (OFAT)
Observed variation in response is caused by the input
Critical to quality.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Brand image.

30. What are two other names for an Ishikawa diagram?
Fishbone - cause-and-effect diagram.
Is the consequence of the failure.
Define - measure - analyze - design - verify.
Mistake-proofing.

31. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Conformance to specifications.
The manager in charge of a process being improved in a Six Sigma project.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Is the consequence of the failure.

32. Creating a Run Chart
If the Response vs. Levels graph if the response lines are not parallel (crossing)
= yij - y(bar)i --> value minus sum of that treatment (of row)
To monitor a process when measurement by variables is used.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

33. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
Taguchi
10 if Almost impossible to detect
100%
The degree to which a product meets pre-established standards.

34. What happens to control limits on an SPC chart when sample size is increased?
Taguchi
They move closer to the center line.
A brainstorming tool that shows the connections between ideas.
Scrap - rework - retest - downtime - yield losses - disposition costs.

35. Cause and Effect Diagrams
Mistake-proofing.
A tool that shows where there is waste in a process.
Method developed by Ishikawa to graphically display the causes of any given problem
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

36. Who developed the fishbone diagram?
Scrap - rework - retest - downtime - yield losses - disposition costs.
Kaoru Ishikawa.
Mistake-proofing.
5%

37. Define features.
Sampling for SPC is done real time.
Attribute
The secondary characteristics of a product; "bells and whistles."
Rapid improvement process.

38. What is a Gage R&R?
Concluding there has not been an effect/change when there has.
Lower control limit.
The House of Quality.
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).

39. List two appraisal costs.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
What the value of the dependent variable is when the independent variable is zero.
95%
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

40. Which quality guru developed the concept of loss to society?
Workers - machines - materials.
No -- the variation also has to be random and "expected."
The gap between what is promised and what is delivered.
Taguchi

41. What is a Pareto chart?
A descending order-sorted bar chart with a cumulative percentage line.
Attribute.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Concluding there has not been an effect/change when there has.

42. If a Cp shows that a process is not capable - should you calculate Cpk?
Attribute
The degree to which a product meets pre-established standards.
Initiated before or at design concept finalization
No -- if it is not the same - it can only be worse!

43. Define serviceability.
Speed - courtesy - competence - and ease of repair.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Sampling for SPC is done real time.

44. What is the role of a master black belt?
Look for the assignable cause of non-random variation.
Is the consequence of the failure.
To mentor/coach (and sometimes train) black belts.
No -- if it is not the same - it can only be worse!

45. What is Little's Law?
Supplier - input - process - output - customer.
A diagram that shows the relationships between activities in a project network.
The manager in charge of a process being improved in a Six Sigma project.
Inventory = throughput x flow time.

46. Defect location check sheets
Actual drawings - layouts - maps - etc which show where a defect occurs
To be a member of a Six Sigma project team.
A tool that shows performance along key dimensions all at once.
The ability of a process to consistently meet customer specifications.

47. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Prevention and appraisal costs are balanced against internal and external failure.
Is the consequence of the failure.
The House of Quality.
The gap between what management thinks customers want and the process specifications.

48. What size should samples be for attribute SPC?
Large enough to find two of the attribute - on average.
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 what is promised and what is delivered.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

49. Complete this quality phrase: 'Fix the process - not the _____.'
Outside.
Blame.
Hold all input variables constant except one. Observe the response as you vary the single input.
Studying firms with the best performance in a particular area.

50. Process check sheets
Look for the assignable cause of non-random variation.
Used to create frequency distribution tally sheets
The degree to which a product meets pre-established standards.
10 for Hazardous without warning 1 for none