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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. For what is a p-chart used?
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Through producer/consumer negotiation.
Kaoru Ishikawa.
To monitor a process when measurement by attribute is used.

2. What is Jidoka?
Actual drawings - layouts - maps - etc which show where a defect occurs
Look for the assignable cause of non-random variation.
The ability of a process to consistently meet customer specifications.
Controlling quality at the source.

3. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
95%
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
To monitor a process when measurement by attribute is used.
Fewer good units to sell - increased variable cost/unit.

4. List two appraisal costs.
The US national quality award.
Failure Modes and Effects Analysis
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Supplier - input - process - output - customer.

5. Why do you need two control charts for variables SPC?
10 for Hazardous without warning 1 for none
Assigns scores to weighted criteria for each project under consideration.
Because the mean and standard deviation are independent of each other.
Producer risk.

6. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
A random variable that summarizes the information from the sample(s).
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Outside.

7. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Method developed by Ishikawa to graphically display the causes of any given problem
5%
Define - measure - analyze - improve - control.
It looks to minimize the probability of a failure - or to minimize its effects

8. In a regression - what does R-square tell you?
Taguchi
They move closer to the center line.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

9. One factor at a time (OFAT)
To obtain a certain desirable outcome from the process
Inventory = throughput x flow time.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Hold all input variables constant except one. Observe the response as you vary the single input.

10. In the Service Quality Gap Model - what is Gap 5?
Shifts - Trends - Repeating patterns - Correlation with known events
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 customers expect and the service they receive.
Is the consequence of the failure.

11. FMEA
It looks to minimize the probability of a failure - or to minimize its effects
The ability of a process to consistently meet customer specifications.
To monitor a process when measurement by attribute is used.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

12. List Garvin's eight dimensions of product quality.
Represents the behavior of a process
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Producer risk.

13. Non-random patterns (Run Charts)
Scrap - rework - retest - downtime - yield losses - disposition costs.
Shifts - Trends - Repeating patterns - Correlation with known events
QFD
Rapid improvement process.

14. What is Type II Error?
Scrap - rework - retest - downtime - yield losses - disposition costs.
Lean (or JIT).
Workers - machines - materials.
Concluding there has not been an effect/change when there has.

15. Design of Experiments (DOE) approach
Observed variation in response is caused by the input
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
A scatterplot.

16. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Studying firms with the best performance in a particular area.
Taguchi
Lean (or JIT).
If the Response vs. Levels graph if the response lines are not parallel (crossing)

17. What is the 5S model?
= 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
The primary operating characteristics of a product.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Consumer risk.

18. Name the structure associated with Quality Function Deployment.
Represents the behavior of a process
False - because each machine will have different natural tolerances.
Is what induces the failure
The House of Quality.

19. List two components of prevention cost.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Studying firms with the best performance in a particular area.
To monitor a process when measurement by attribute is used.

20. In the Service Quality Gap Model - what is Gap 3?
The primary operating characteristics of a product.
99.73%
The gap between specifications and how service is performed.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

21. What is Type 1 Error?
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
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Concluding there has been an effect/change when there has not.
Taguchi

22. What is poka yoke?
A diagram that shows the relationships between activities in a project network.
3.4 (assuming 1.5 sigma shift in the mean)
A scatterplot.
Mistake-proofing.

23. What quality guru emphasizes management as a system?
Initiated before or at design concept finalization
F_alpha - df(tr) - df (error)
Deming.
Large enough to find two of the attribute - on average.

24. What is a spaghetti diagram?
The cycle time required to meet demand.
Technical quality is the "what" of the service; functional quality is the "how."
A tool that shows the physical flows through a space.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

25. What is Value Stream Mapping?
10 if Almost impossible to detect
A tool that shows where there is waste in a process.
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
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

26. What does SIPOC stand for?
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
Supplier - input - process - output - customer.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Mistake-proofing.

27. What size should samples be for attribute SPC?
An assertion or conjecture concerning one or more populations
The gap between what management thinks customers want and the process specifications.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Large enough to find two of the attribute - on average.

28. Regression Analysis
Is the consequence of the failure.
95%
A tool that shows the physical flows through a space.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

29. If a three-stage process has 90% yields at each stage - what is the overall yield?
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Shows the temporal flow of activities in a project network.
Financial - customer - internal process - innovation and learning.
0.9^3 or 72.9%

30. FMEA
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
Central Limit Theorem
X-bar-bar
A random variable that summarizes the information from the sample(s).

31. 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
Blame.
100%
Someone who is consistently against virtually everything.

32. Defect location check sheets
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).
Pleasing to the senses.
Actual drawings - layouts - maps - etc which show where a defect occurs
Failure Modes and Effects Analysis

33. What is written on the "spines" of a fishbone diagram?
Taguchi
Causes that lead to a particular effect.
It's good -- but it's still out of control!
Blame.

34. Failure Mode
Is the way in which the failure is manifested.
The gap between specifications and how service is performed.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Variable.

35. Failure effect
To do a capability study for a non-centered process.
Taguchi
Is the consequence of the failure.
Actual drawings - layouts - maps - etc which show where a defect occurs

36. With Six Sigma capability - how many defects per million opportunities would you see?
3.4 (assuming 1.5 sigma shift in the mean)
Outside.
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
Variable.

37. What does Crosby say about benchmarking?
They move closer to the center line.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Attribute
Upper control limit.

38. Define conformance quality.
Fractional factorial designs (orthogonal arrays)
Observed variation in response is caused by the input
The degree to which a product meets pre-established standards.
Prevention - appraisal - internal failure - external failure.

39. Detection Criteria Ranking
Method developed by Ishikawa to graphically display the causes of any given problem
3.4 (assuming 1.5 sigma shift in the mean)
No -- the variation also has to be random and "expected."
10 if Almost impossible to detect

40. Define benchmarking.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Is what induces the failure
QFD
Studying firms with the best performance in a particular area.

41. One factor at a time (OFAT)
Observed variation in response is caused by the input
50%
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The target number of standard deviations from the mean for specifications.

42. In the Service Quality Gap Model - what is Gap 2?
The gap between what management thinks customers want and the process specifications.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
3.4 (assuming 1.5 sigma shift in the mean)
X-bar-bar

43. What is a Gage R&R?
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:
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).
Defects Per Million Opportunities
The number of standard deviations some value is from the mean.

44. Based on what principal can we use the normal distribution assumptions for SPC?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Central Limit Theorem
Variable.
Variable.

45. How does Juran define quality?
Someone who is consistently against virtually everything.
Fractional factorial designs (orthogonal arrays)
Fitness for use.
Because the mean and standard deviation are independent of each other.

46. Manual Test for Nomality
Studying firms with the best performance in a particular area.
Can't tell without a Range chart.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Financial - customer - internal process - innovation and learning.

47. Which quality guru developed the concept of loss to society?
Taguchi
No -- only if the process is also capable.
False - because each machine will have different natural tolerances.
The ratio of outputs to inputs; 1-scrap.

48. Simple Regression Analysis (one factor regression model)
Studying firms with the best performance in a particular area.
Upper control limit.
68%
= 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

49. What is the role of a black belt?
The gap between what is promised and what is delivered.
Fishbone - cause-and-effect diagram.
To manage the Six Sigma project.
A descending order-sorted bar chart with a cumulative percentage line.

50. What is Little's Law?
Fitness for use.
To be a member of a Six Sigma project team.
Inventory = throughput x flow time.
Sampling for SPC is done real time.