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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. Defect check sheets
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Different types of defects are listed (used for Pareto chart)
To do a capability study for a non-centered process.
Define - measure - analyze - improve - control.

2. 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
It looks to minimize the probability of a failure - or to minimize its effects
Prevention and appraisal costs are balanced against internal and external failure.
Shifts - Trends - Repeating patterns - Correlation with known events

3. Non-random patterns (Run Charts)
Consumer risk.
Shifts - Trends - Repeating patterns - Correlation with known events
It looks to minimize the probability of a failure - or to minimize its effects
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

4. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
Walter A. Shewhart
The number of standard deviations some value is from the mean.
100%
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

5. What is the role of a green belt?
Deming.
To be a member of a Six Sigma project team.
To manage the Six Sigma project.
= yij - y(bar)i --> value minus sum of that treatment (of row)

6. What does DMAIC stand for?
Shifts - Trends - Repeating patterns - Correlation with known events
Define - measure - analyze - improve - control.
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
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

7. How are LQL and AQL determined in an acceptance sampling plan?
Variable.
The Japanese national quality award.
Supplier - input - process - output - customer.
Through producer/consumer negotiation.

8. What is a Gage R&R?
Defects Per Million Opportunities
Shifts - Trends - Repeating patterns - Correlation with known events
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 do a capability study for a non-centered process.

9. What are the four perspectives of the Balanced Scorecard?
Through producer/consumer negotiation.
Financial - customer - internal process - innovation and learning.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

10. In the Service Quality Gap Model - what is Gap 5?
The ability of a process to consistently meet customer specifications.
Look for the assignable cause of non-random variation.
The gap between what customers expect and the service they receive.
Waste.

11. What is Type 1 Error?
False - because each machine will have different natural tolerances.
Concluding there has not been an effect/change when there has.
Concluding there has been an effect/change when there has not.
Technical quality is the "what" of the service; functional quality is the "how."

12. Affinity Diagrams
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
Mean time to failure.
Organize ideas into meaningful categories by recognizing their underlying similarity
Outside.

13. Uses of regression - Control
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
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
To obtain a certain desirable outcome from the process
0.9^3 or 72.9%

14. Risk Priority Number RPN
A tool that shows where there is waste in a process.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Different types of defects are listed (used for Pareto chart)
Not necessarily.

15. What are the four regression assumptions?
Stratify a particular defect type according to logical criteria
5%
The cycle time required to meet demand.
Linearity - normality - homoscedasticity - independence.

16. Why do you need two control charts for variables SPC?
Before production starts
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
Because the mean and standard deviation are independent of each other.
A brainstorming tool that shows the connections between ideas.

17. Detection Criteria Ranking
Lower control limit.
A random variable that summarizes the information from the sample(s).
10 if Almost impossible to detect
Variable.

18. In the Service Quality Gap Model - what is Gap 3?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Mean time to failure.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
The gap between specifications and how service is performed.

19. Test for constant variance
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
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.

20. What is the Deming Prize?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Prevention and appraisal costs are balanced against internal and external failure.
The Japanese national quality award.
The gap between what management thinks customers want and the process specifications.

21. List two components of internal failure.
Used to create frequency distribution tally sheets
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

22. Creating a Run Chart
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Mean time to replacement.
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
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

23. Define aesthetic quality.
Attribute.
Pleasing to the senses.
Blame.
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

24. What is an affinity diagram?
A brainstorming tool that shows the connections between ideas.
Attribute
= 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
Upper control limit.

25. What is process capability?
To manage the Six Sigma project.
Speed - courtesy - competence - and ease of repair.
The ability of a process to consistently meet customer specifications.
Deming.

26. Define features.
To do a capability study for a non-centered process.
10 for Hazardous without warning 1 for none
To mentor/coach (and sometimes train) black belts.
The secondary characteristics of a product; "bells and whistles."

27. Definition of Interaction
A tool that shows where there is waste in a process.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
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. Taguchi's experimental designs are of this type.
A tool that shows where there is waste in a process.
Fitness for use.
Fractional factorial designs (orthogonal arrays)
It looks to minimize the probability of a failure - or to minimize its effects

29. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Attribute
Prevention and appraisal costs are balanced against internal and external failure.
To mentor/coach (and sometimes train) black belts.
X-bar-bar

30. What is a histogram?
Prevention - appraisal - internal failure - external failure.
Is the way in which the failure is manifested.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
A random variable that summarizes the information from the sample(s).

31. Regression
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 number of standard deviations some value is from the mean.
To be a member of a Six Sigma project team.
Represents the behavior of a process

32. Failure cause
The degree to which a product meets pre-established standards.
10 if Almost impossible to detect
Is what induces the failure
What the value of the dependent variable is when the independent variable is zero.

33. What is the 5S model?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Fewer good units to sell - increased variable cost/unit.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
p-bar - the long-run percent defective.

34. List Garvin's eight dimensions of product quality.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Can't tell without a Range chart.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

35. Failure Mode
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Is the way in which the failure is manifested.
The number of standard deviations some value is from the mean.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

36. What is muda
Large enough to find two of the attribute - on average.
Waste.
No -- if it is not the same - it can only be worse!
Hold all input variables constant except one. Observe the response as you vary the single input.

37. DOE
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
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
No -- only if the process is also capable.

38. Define product reliability.
Mean time to failure.
Pleasing to the senses.
Studying firms with the best performance in a particular area.
Define - measure - analyze - improve - control.

39. Design of Experiments (DOE) approach
Rapid improvement process.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Fractional factorial designs (orthogonal arrays)
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

40. Your production process meets customer specifications. Is your process in control?
Not necessarily.
The cycle time required to meet demand.
A tool that shows where there is waste in a process.
Fewer good units to sell - increased variable cost/unit.

41. When yields decrease - what are the two effects on contribution?
Sort - Set in Order - Shine - Standardize - Sustain
10 if Almost impossible to detect
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
Fewer good units to sell - increased variable cost/unit.

42. Residual
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Can't tell without a Range chart.
No -- if it is not the same - it can only be worse!
= yij - y(bar)i --> value minus sum of that treatment (of row)

43. What percentage of a normal distribution lies above the mean?
Can't tell without a Range chart.
The target number of standard deviations from the mean for specifications.
50%
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

44. What is the center line of a p-chart?
Define - measure - analyze - improve - control.
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
p-bar - the long-run percent defective.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

45. In a regression - what does the p value of F tell you?
Concluding there has been an effect/change when there has not.
To monitor a process when measurement by variables is used.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
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).

46. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Pleasing to the senses.
5%
Variable.
The gap between what management thinks customers want and what customers really want.

47. What is a spaghetti diagram?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
A tool that shows the physical flows through a space.
p-bar - the long-run percent defective.
Used to create frequency distribution tally sheets

48. Who first studied randomness in industrial processes
Walter A. Shewhart
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
No -- only if the process is also capable.
What the value of the dependent variable is when the independent variable is zero.

49. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
To monitor a process when measurement by variables is used.
=sqrt(Σ(x-x-bar)^2)/(n-1))
No -- the variation also has to be random and "expected."
The gap between what management thinks customers want and the process specifications.

50. Cause and Effect Diagrams
100%
Method developed by Ishikawa to graphically display the causes of any given problem
Fishbone - cause-and-effect diagram.
Fractional factorial designs (orthogonal arrays)