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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. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
A tool that shows where there is waste in a process.
Define - measure - analyze - improve - control.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Lower skill requirements - faster - less chance for error.

2. What is the Baldrige Award?
Central Limit Theorem
Controlling quality at the source.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The US national quality award.

3. What is the role of a green belt?
It looks to minimize the probability of a failure - or to minimize its effects
It's good -- but it's still out of control!
The manager in charge of a process being improved in a Six Sigma project.
To be a member of a Six Sigma project team.

4. If you can only collect categorical data - what type of SPC charting can you do?
Attribute.
Defects Per Million Opportunities
Reliability - Assurance - Responsiveness - Tangibles - Empathy
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

5. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Stratify a particular defect type according to logical criteria
Outside.
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).
Rapid improvement process.

6. What are the Five Dimensions of Service Quality?
Scrap - rework - retest - downtime - yield losses - disposition costs.
10 for Hazardous without warning 1 for none
Concluding there has not been an effect/change when there has.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

7. Disadvantages of DOE

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8. What is Value Stream Mapping?
A tool that shows where there is waste in a process.
X-bar-bar
Observed variation in response is caused by the input
Attribute

9. List Garvin's eight dimensions of product quality.
Mean time to failure.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Defects Per Million Opportunities
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

10. Failure effect
Is the consequence of the failure.
The gap between what customers expect and the service they receive.
A tool that shows performance along key dimensions all at once.
Represents the behavior of a process

11. What is a Gage R&R?
Conformance to specifications.
5%
No -- the variation also has to be random and "expected."
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).

12. One factor at a time (OFAT)
To monitor a process when measurement by attribute is used.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
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).
Observed variation in response is caused by the input

13. What is the center line of an X-bar chart?
Used to create frequency distribution tally sheets
50%
Through producer/consumer negotiation.
X-bar-bar

14. What is a dashboard?
Central Limit Theorem
99.73%
Failure Modes and Effects Analysis
A tool that shows performance along key dimensions all at once.

15. Daniel Test
Central Limit Theorem
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
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:
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

16. What graphical tool is used to show the relationship between two numerical variables?
A scatterplot.
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.
=sqrt((p*(1-p)/n)
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:

17. Name the structure associated with Quality Function Deployment.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Fishbone - cause-and-effect diagram.
The House of Quality.
Stratify a particular defect type according to logical criteria

18. Taguchi's experimental designs are of this type.
The ability of a process to consistently meet customer specifications.
A brainstorming tool that shows the connections between ideas.
Fractional factorial designs (orthogonal arrays)
To monitor a process when measurement by attribute is used.

19. Defect check sheets
Different types of defects are listed (used for Pareto chart)
Supplier - input - process - output - customer.
Critical to quality.
Walter A. Shewhart

20. When is Cpk used?
Large enough to find two of the attribute - on average.
To do a capability study for a non-centered process.
Not necessarily.
Lean (or JIT).

21. Advantages of DOE
A random variable that summarizes the information from the sample(s).
Mean time to replacement.
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

22. Uses of regression - Control
Technical quality is the "what" of the service; functional quality is the "how."
Is the way in which the failure is manifested.
Outside.
To obtain a certain desirable outcome from the process

23. Residual
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Hold all input variables constant except one. Observe the response as you vary the single input.
Different types of defects are listed (used for Pareto chart)
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

24. Statistical Hypothesis
An assertion or conjecture concerning one or more populations
Hold all input variables constant except one. Observe the response as you vary the single input.
QFD
The House of Quality.

25. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
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
Waste.

26. Non-random patterns (Run Charts)
Defects Per Million Opportunities
=sqrt((p*(1-p)/n)
Shifts - Trends - Repeating patterns - Correlation with known events
Fitness for use.

27. What are the four categories of costs in Juran's framework?
99.73%
Waste.
No -- the variation also has to be random and "expected."
Prevention - appraisal - internal failure - external failure.

28. The Test Statistic (TS)
A random variable that summarizes the information from the sample(s).
Shifts - Trends - Repeating patterns - Correlation with known events
Through producer/consumer negotiation.
5%

29. What are the four perspectives of the Balanced Scorecard?
Outside.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Financial - customer - internal process - innovation and learning.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

30. Regression Analysis
The target number of standard deviations from the mean for specifications.
Large enough to find two of the attribute - on average.
The secondary characteristics of a product; "bells and whistles."
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

31. What is an affinity diagram?
A brainstorming tool that shows the connections between ideas.
Before production starts
Is what induces the failure
To do a capability study for a non-centered process.

32. For what is an x-bar chart used?
Is the way in which the failure is manifested.
Can't tell without a Range chart.
To monitor a process when measurement by variables is used.
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:

33. In a regression - what does R-square tell you?
To obtain a certain desirable outcome from the process
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Financial - customer - internal process - innovation and learning.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

34. Pareto Analysis
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).
Look for the assignable cause of non-random variation.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Linearity - normality - homoscedasticity - independence.

35. What is written on the "spines" of a fishbone diagram?
The ability of a process to consistently meet customer specifications.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Causes that lead to a particular effect.
100%

36. Risk Priority Number RPN
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Blame.
A tool that shows performance along key dimensions all at once.
Defects Per Million Opportunities

37. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Assigns scores to weighted criteria for each project under consideration.
Lower control limit.
Consumer risk.
Variable.

38. What is FMEA?
Pleasing to the senses.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Failure Modes and Effects Analysis
Scrap - rework - retest - downtime - yield losses - disposition costs.

39. What does the abbreviation LCL stand for?
Deming.
A random variable that summarizes the information from the sample(s).
A tool that shows where there is waste in a process.
Lower control limit.

40. Uses of regression
Producer risk.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
A tool that shows where there is waste in a process.
Mean time to replacement.

41. In Juran's Cost of Quality model - which categories of costs balance which other categories?
The primary operating characteristics of a product.
Prevention and appraisal costs are balanced against internal and external failure.
No -- only if the process is also capable.
Fractional factorial designs (orthogonal arrays)

42. Test for constant variance
Concluding there has been an effect/change when there has not.
Failure Modes and Effects Analysis
A tool that shows performance along key dimensions all at once.
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.

43. What is DMADV?
Define - measure - analyze - design - verify.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
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).
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

44. What is the center line of a p-chart?
To do a capability study for a non-centered process.
p-bar - the long-run percent defective.
Prevention - appraisal - internal failure - external failure.
Outside.

45. Presence of interaction effect
Hold all input variables constant except one. Observe the response as you vary the single input.
To do a capability study for a non-centered process.
Assigns scores to weighted criteria for each project under consideration.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

46. Effect ranking (Severity of the Defect)
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
10 for Hazardous without warning 1 for none
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

47. Complete this quality phrase: 'Fix the process - not the _____.'
Blame.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Attribute
A random variable that summarizes the information from the sample(s).

48. What type of risk is associated with Type II Error?
95%
The cycle time required to meet demand.
It's good -- but it's still out of control!
Consumer risk.

49. What is Kaizen?
QFD
The gap between what customers expect and the service they receive.
Rapid improvement process.
The ratio of outputs to inputs; 1-scrap.

50. What is the role of a master black belt?
Variable.
Producer risk.
Define - measure - analyze - design - verify.
To mentor/coach (and sometimes train) black belts.