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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. If you have calculated a Cpk - should you also calculate a Cp?
The ability of a process to consistently meet customer specifications.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Scrap - rework - retest - downtime - yield losses - disposition costs.
To obtain a certain desirable outcome from the process

2. Stratified defect check sheets
0.9^3 or 72.9%
Critical to quality.
Stratify a particular defect type according to logical criteria
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

3. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
100%
Consumer risk.
5%
It looks to minimize the probability of a failure - or to minimize its effects

4. What is Type 1 Error?
Concluding there has been an effect/change when there has not.
Causes that lead to a particular effect.
The ability of a process to consistently meet customer specifications.
Define - measure - analyze - improve - control.

5. Define perceived quality (Garvin's framework).
Brand image.
The primary operating characteristics of a product.
Variable.
Critical to quality.

6. Who first studied randomness in industrial processes
Walter A. Shewhart
Concluding there has not been an effect/change when there has.
Pleasing to the senses.
Represents the behavior of a process

7. Failure Mode
Attribute
Someone who is consistently against virtually everything.
100%
Is the way in which the failure is manifested.

8. Uses of regression
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Someone who is consistently against virtually everything.
The gap between what customers expect and the service they receive.

9. What is the role of a green belt?
A tool that shows the physical flows through a space.
They move closer to the center line.
To be a member of a Six Sigma project team.
Define - measure - analyze - improve - control.

10. What does DMAIC stand for?
Defects Per Million Opportunities
Define - measure - analyze - improve - control.
Not necessarily.
Technical quality is the "what" of the service; functional quality is the "how."

11. What is process capability?
Fractional factorial designs (orthogonal arrays)
The ability of a process to consistently meet customer specifications.
Central Limit Theorem
No -- the variation also has to be random and "expected."

12. Explain the difference between technical and functional service quality.
No -- only if the process is also capable.
False - because each machine will have different natural tolerances.
The gap between what customers expect and the service they receive.
Technical quality is the "what" of the service; functional quality is the "how."

13. Design of Experiments (DOE) approach
Upper control limit.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The Japanese national quality award.
A descending order-sorted bar chart with a cumulative percentage line.

14. What is a histogram?
Upper control limit.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Causes that lead to a particular effect.

15. Define takt time.
Blame.
Different types of defects are listed (used for Pareto chart)
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 cycle time required to meet demand.

16. Why do you need two control charts for variables SPC?
Walter A. Shewhart
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Because the mean and standard deviation are independent of each other.
Define - measure - analyze - improve - control.

17. If a three-stage process has 90% yields at each stage - what is the overall yield?
The gap between what customers expect and the service they receive.
Mean time to failure.
The gap between what is promised and what is delivered.
0.9^3 or 72.9%

18. In a regression - what does the standard error of the estimate tell you?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
The Japanese national quality award.
A time series plot.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

19. Disadvantages of DOE

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20. In a regression - what does the p value of F tell you?
Prevention - appraisal - internal failure - external failure.
Consumer risk.
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).
Fewer good units to sell - increased variable cost/unit.

21. What is FMEA?
10 for Hazardous without warning 1 for none
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Failure Modes and Effects Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

22. What is a spaghetti diagram?
50%
A tool that shows the physical flows through a space.
Concluding there has been an effect/change when there has not.
0.9^3 or 72.9%

23. What is CTQ?
Critical to quality.
The ratio of outputs to inputs; 1-scrap.
Controlling quality at the source.
p-bar - the long-run percent defective.

24. Process occurance ranking
= yij - y(bar)i --> value minus sum of that treatment (of row)
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).
Used to create frequency distribution tally sheets
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

25. What is a run chart?
A time series plot.
No -- the variation also has to be random and "expected."
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Is what induces the failure

26. Name the structure associated with Quality Function Deployment.
=sqrt((p*(1-p)/n)
What the value of the dependent variable is when the independent variable is zero.
The ability of a process to consistently meet customer specifications.
The House of Quality.

27. To what does the Six in Six Sigma relate?
The target number of standard deviations from the mean for specifications.
Conformance to specifications.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
The ability of a process to consistently meet customer specifications.

28. One factor at a time (OFAT)
The secondary characteristics of a product; "bells and whistles."
Observed variation in response is caused by the input
Failure Modes and Effects Analysis
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

29. When yields decrease - what are the two effects on contribution?
The gap between specifications and how service is performed.
Fewer good units to sell - increased variable cost/unit.
Represents the behavior of a process
Rapid improvement process.

30. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
3.4 (assuming 1.5 sigma shift in the mean)
An assertion or conjecture concerning one or more populations
Lean (or JIT).
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

31. What is the difference between Lean and Six Sigma?
Attribute.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Lean is waste reduction - Six Sigma is variation reduction.
Concluding there has been an effect/change when there has not.

32. For what is an x-bar chart used?
To monitor a process when measurement by variables is used.
Is what induces the failure
Mistake-proofing.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

33. List two components of external failure.
Rapid improvement process.
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 Japanese national quality award.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

34. What is DMADV?
Critical to quality.
Define - measure - analyze - design - verify.
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
Attribute

35. Statistical Hypothesis
An assertion or conjecture concerning one or more populations
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
What the value of the dependent variable is when the independent variable is zero.
A descending order-sorted bar chart with a cumulative percentage line.

36. What is the center line of an X-bar chart?
X-bar-bar
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Attribute.
Variable.

37. Does it ever make sense to accept a job when a process is incapable?
Linearity - normality - homoscedasticity - independence.
Represents the behavior of a process
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

38. What does the abbreviation UCL stand for?
Upper control limit.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Supplier - input - process - output - customer.
10 for Hazardous without warning 1 for none

39. Define serviceability.
Lower control limit.
The gap between what management thinks customers want and the process specifications.
50%
Speed - courtesy - competence - and ease of repair.

40. Which type of SPC measurement is more precise - variable or attribute?
Variable.
Attribute
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
If the Response vs. Levels graph if the response lines are not parallel (crossing)

41. List two components of internal failure.
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).
Scrap - rework - retest - downtime - yield losses - disposition costs.
Fishbone - cause-and-effect diagram.
The manager in charge of a process being improved in a Six Sigma project.

42. Uses of regression - Control
Define - measure - analyze - design - verify.
Look for the assignable cause of non-random variation.
To obtain a certain desirable outcome from the process
Blame.

43. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Attribute
The gap between what customers expect and the service they receive.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The gap between what is promised and what is delivered.

44. What type of risk is associated with Type II Error?
Consumer risk.
10 for Hazardous without warning 1 for none
Organize ideas into meaningful categories by recognizing their underlying similarity
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. Detection Criteria Ranking
10 if Almost impossible to detect
50%
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Scrap - rework - retest - downtime - yield losses - disposition costs.

46. ANOVA

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47. Process check sheets
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
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Used to create frequency distribution tally sheets

48. What does a project prioritization matrix do?
F_alpha - df(tr) - df (error)
Assigns scores to weighted criteria for each project under consideration.
The primary operating characteristics of a product.
Variable.

49. Daniel Test
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
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 be a member of a Six Sigma project team.

50. Manual Test for Nomality
Prevention and appraisal costs are balanced against internal and external failure.
Variable.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Reliability - Assurance - Responsiveness - Tangibles - Empathy