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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. What size should samples be for attribute SPC?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Concluding there has been an effect/change when there has not.
Can't tell without a Range chart.
Large enough to find two of the attribute - on average.

2. What is the center line of a p-chart?
Before production starts
To monitor a process when measurement by variables is used.
p-bar - the long-run percent defective.
Large enough to find two of the attribute - on average.

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

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4. Test for Independence
Variable.
A tool that shows where there is waste in a process.
A brainstorming tool that shows the connections between ideas.
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

5. Name the structure associated with Quality Function Deployment.
The House of Quality.
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 number of standard deviations some value is from the mean.
Kaoru Ishikawa.

6. Complete this quality phrase: 'Fix the process - not the _____.'
Deming.
Assigns scores to weighted criteria for each project under consideration.
Blame.
To be a member of a Six Sigma project team.

7. 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).
To monitor a process when measurement by attribute is used.
What the value of the dependent variable is when the independent variable is zero.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

8. What do you do when a process is out of control?
Variable.
5%
A tool that shows the physical flows through a space.
Look for the assignable cause of non-random variation.

9. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
Attribute
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Shifts - Trends - Repeating patterns - Correlation with known events

10. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Scrap - rework - retest - downtime - yield losses - disposition costs.
False - because each machine will have different natural tolerances.
Conformance to specifications.
Is the consequence of the failure.

11. FMEA
Observed variation in response is caused by the input
Hold all input variables constant except one. Observe the response as you vary the single input.
A tool that shows performance along key dimensions all at once.
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

12. F value
Concluding there has not been an effect/change when there has.
Large enough to find two of the attribute - on average.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
F_alpha - df(tr) - df (error)

13. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
95%
Define - measure - analyze - design - verify.
Before production starts
False - because each machine will have different natural tolerances.

14. What type of risk is associated with Type II Error?
X-bar-bar
Is what induces the failure
Consumer risk.
A tool that shows performance along key dimensions all at once.

15. What is muda
The gap between what is promised and what is delivered.
Waste.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
10 for Hazardous without warning 1 for none

16. Define conformance quality.
The degree to which a product meets pre-established standards.
The primary operating characteristics of a product.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The number of standard deviations some value is from the mean.

17. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Variable.
Lower skill requirements - faster - less chance for error.
The number of standard deviations some value is from the mean.
5%

18. What is a dashboard?
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.
Studying firms with the best performance in a particular area.
Assigns scores to weighted criteria for each project under consideration.

19. Define perceived quality (Garvin's framework).
The US national quality award.
Brand image.
Upper control limit.
Speed - courtesy - competence - and ease of repair.

20. A process is operating "in control." Does this mean the customer's requirements are met?
No -- only if the process is also capable.
Method developed by Ishikawa to graphically display the causes of any given problem
Attribute.
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

21. Defect location check sheets
Observed variation in response is caused by the input
Variable.
Actual drawings - layouts - maps - etc which show where a defect occurs
=sqrt((p*(1-p)/n)

22. Which quality guru developed the concept of loss to society?
The gap between specifications and how service is performed.
Before production starts
Taguchi
Is what induces the failure

23. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Kaoru Ishikawa.
95%

24. If you can only collect categorical data - what type of SPC charting can you do?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The cycle time required to meet demand.
5%
Attribute.

25. What is a histogram?
The secondary characteristics of a product; "bells and whistles."
Attribute.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
The gap between what management thinks customers want and what customers really want.

26. 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.
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
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.

27. Define benchmarking.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Is the way in which the failure is manifested.
Different types of defects are listed (used for Pareto chart)
Studying firms with the best performance in a particular area.

28. Why do you need two control charts for variables SPC?
False - because each machine will have different natural tolerances.
The ratio of outputs to inputs; 1-scrap.
Brand image.
Because the mean and standard deviation are independent of each other.

29. To what does the Six in Six Sigma relate?
Scrap - rework - retest - downtime - yield losses - disposition costs.
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 target number of standard deviations from the mean for specifications.
The gap between what management thinks customers want and the process specifications.

30. Regression
To monitor a process when measurement by variables is used.
To monitor a process when measurement by attribute is used.
A random variable that summarizes the information from the sample(s).
Represents the behavior of a process

31. List two components of external failure.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Variable.
Attribute.

32. In the Service Quality Gap Model - what is Gap 5?
The gap between what customers expect and the service they receive.
Stratify a particular defect type according to logical criteria
Linearity - normality - homoscedasticity - independence.
Supplier - input - process - output - customer.

33. When yields decrease - what are the two effects on contribution?
Attribute.
No -- only if the process is also capable.
Fewer good units to sell - increased variable cost/unit.
The gap between what is promised and what is delivered.

34. Defect check sheets
Reliability - Assurance - Responsiveness - Tangibles - Empathy
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.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

35. Design of Experiments (DOE) approach
Walter A. Shewhart
100%
Sort - Set in Order - Shine - Standardize - Sustain
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

36. Process occurance ranking
To monitor a process when measurement by variables is used.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
No -- only if the process is also capable.
What the value of the dependent variable is when the independent variable is zero.

37. What graphical tool is used to show the relationship between two numerical variables?
A scatterplot.
Waste.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Central Limit Theorem

38. Non-random patterns (Run Charts)
Shifts - Trends - Repeating patterns - Correlation with known events
Prevention and appraisal costs are balanced against internal and external failure.
Someone who is consistently against virtually everything.
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

39. In the Service Quality Gap Model - what is Gap 2?
Blame.
To be a member of a Six Sigma project team.
Rapid improvement process.
The gap between what management thinks customers want and the process specifications.

40. Test for constant variance
The Japanese national quality award.
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.
Kaoru Ishikawa.
Scrap - rework - retest - downtime - yield losses - disposition costs.

41. How are LQL and AQL determined in an acceptance sampling plan?
Represents the behavior of a process
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The US national quality award.
Through producer/consumer negotiation.

42. What are the four regression assumptions?
Financial - customer - internal process - innovation and learning.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
95%
Linearity - normality - homoscedasticity - independence.

43. What is Little's Law?
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).
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
p-bar - the long-run percent defective.

44. What are the four categories of costs in Juran's framework?
Mistake-proofing.
10 for Hazardous without warning 1 for none
Shifts - Trends - Repeating patterns - Correlation with known events
Prevention - appraisal - internal failure - external failure.

45. What is the formula for the standard deviation of a proportion?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
=sqrt((p*(1-p)/n)
95%
Concluding there has not been an effect/change when there has.

46. With Six Sigma capability - how many defects per million opportunities would you see?
Taguchi
3.4 (assuming 1.5 sigma shift in the mean)
The cycle time required to meet demand.
To monitor a process when measurement by attribute is used.

47. Disadvantages of DOE

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48. If a Cp shows that a process is not capable - should you calculate Cpk?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
68%
Conformance to specifications.
No -- if it is not the same - it can only be worse!

49. Taguchi's experimental designs are of this type.
Fractional factorial designs (orthogonal arrays)
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
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Speed - courtesy - competence - and ease of repair.

50. Define yield.
Concluding there has been an effect/change when there has not.
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
Consumer risk.
The ratio of outputs to inputs; 1-scrap.