Test your basic knowledge |

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 does SIPOC stand for?
Supplier - input - process - output - customer.
Lean is waste reduction - Six Sigma is variation reduction.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
The gap between specifications and how service is performed.

2. Explain the difference between technical and functional service quality.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Technical quality is the "what" of the service; functional quality is the "how."
No -- the variation also has to be random and "expected."
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

3. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Sampling for SPC is done real time.
No -- the variation also has to be random and "expected."
The Japanese national quality award.
Different types of defects are listed (used for Pareto chart)

4. Your production process meets customer specifications. Is your process in control?
An assertion or conjecture concerning one or more populations
A brainstorming tool that shows the connections between ideas.
Not necessarily.
Can't tell without a Range chart.

5. If a Cp shows that a process is not capable - should you calculate Cpk?
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
To monitor a process when measurement by attribute is used.
No -- if it is not the same - it can only be worse!
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

6. What is a network diagram?
Not necessarily.
A diagram that shows the relationships between activities in a project network.
Variable.
A tool that shows where there is waste in a process.

7. What are the four categories of costs in Juran's framework?
Producer risk.
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.
Prevention - appraisal - internal failure - external failure.
A descending order-sorted bar chart with a cumulative percentage line.

8. In the Service Quality Gap Model - what is Gap 5?
It's good -- but it's still out of control!
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.
The gap between what customers expect and the service they receive.
The ratio of outputs to inputs; 1-scrap.

9. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Lean is waste reduction - Six Sigma is variation reduction.
An assertion or conjecture concerning one or more populations
Variable.
A descending order-sorted bar chart with a cumulative percentage line.

10. Creating a Run Chart
Define - measure - analyze - improve - control.
To do a capability study for a non-centered process.
Large enough to find two of the attribute - on average.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

11. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
=sqrt((p*(1-p)/n)
The ratio of outputs to inputs; 1-scrap.
Lean (or JIT).
Is what induces the failure

12. What do you do when a process is out of control?
Because the mean and standard deviation are independent of each other.
Prevention and appraisal costs are balanced against internal and external failure.
Attribute
Look for the assignable cause of non-random variation.

13. What are the three main categories of assignable cause?
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
Workers - machines - materials.
Sort - Set in Order - Shine - Standardize - Sustain
It looks to minimize the probability of a failure - or to minimize its effects

14. What type of risk is associated with Type 1 Error?
Upper control limit.
Fishbone - cause-and-effect diagram.
Producer risk.
The gap between specifications and how service is performed.

15. Who first studied randomness in industrial processes
F_alpha - df(tr) - df (error)
No -- the variation also has to be random and "expected."
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Walter A. Shewhart

16. What is the center line of an X-bar chart?
To monitor a process when measurement by variables is used.
10 if Almost impossible to detect
X-bar-bar
A descending order-sorted bar chart with a cumulative percentage line.

17. Failure cause
Is what induces the failure
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Failure Modes and Effects Analysis
Controlling quality at the source.

18. Affinity Diagrams
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Prevention - appraisal - internal failure - external failure.
The primary operating characteristics of a product.
A descending order-sorted bar chart with a cumulative percentage line.

19. Disadvantages of DOE

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20. What quality guru emphasizes management as a system?
68%
Concluding there has been an effect/change when there has not.
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.
Deming.

21. Manual Test for Nomality
Mistake-proofing.
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 process of ranking opportunities to determine which of many potential opportunities should be pursued first.
68%

22. FMEA
It looks to minimize the probability of a failure - or to minimize its effects
p-bar - the long-run percent defective.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Technical quality is the "what" of the service; functional quality is the "how."

23. Defect location check sheets
The ratio of outputs to inputs; 1-scrap.
QFD
Actual drawings - layouts - maps - etc which show where a defect occurs
Defects Per Million Opportunities

24. List Garvin's eight dimensions of product quality.
A descending order-sorted bar chart with a cumulative percentage line.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Central Limit Theorem

25. 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
Organize ideas into meaningful categories by recognizing their underlying similarity
Financial - customer - internal process - innovation and learning.
Outside.

26. If a three-stage process has 90% yields at each stage - what is the overall yield?
10 if Almost impossible to detect
0.9^3 or 72.9%
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
No -- only if the process is also capable.

27. Define product reliability.
Financial - customer - internal process - innovation and learning.
Mean time to failure.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
50%

28. What is Value Stream Mapping?
Blame.
A tool that shows where there is waste in a process.
=sqrt((p*(1-p)/n)
Deming.

29. What is Jidoka?
A tool that shows performance along key dimensions all at once.
Organize ideas into meaningful categories by recognizing their underlying similarity
Inventory = throughput x flow time.
Controlling quality at the source.

30. Statistical Hypothesis
An assertion or conjecture concerning one or more populations
Upper control limit.
To mentor/coach (and sometimes train) black belts.
Fewer good units to sell - increased variable cost/unit.

31. Definition of Interaction
Define - measure - analyze - design - verify.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
=sqrt(Σ(x-x-bar)^2)/(n-1))
An assertion or conjecture concerning one or more populations

32. What is Little's Law?
Define - measure - analyze - design - verify.
Large enough to find two of the attribute - on average.
Inventory = throughput x flow time.
Attribute.

33. How are LQL and AQL determined in an acceptance sampling plan?
Pleasing to the senses.
Through producer/consumer negotiation.
To monitor a process when measurement by variables is used.
Kaoru Ishikawa.

34. Simple Regression Analysis (one factor regression 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
Defects Per Million Opportunities
To obtain a certain desirable outcome from the process
The gap between what customers expect and the service they receive.

35. A process is operating "in control." Does this mean the customer's requirements are met?
A descending order-sorted bar chart with a cumulative percentage line.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
No -- only if the process is also capable.
0.9^3 or 72.9%

36. What is the role of a black belt?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
A time series plot.
To manage the Six Sigma project.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

37. DFMEA
10 for Hazardous without warning 1 for none
Initiated before or at design concept finalization
Lower skill requirements - faster - less chance for error.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

38. Taguchi's experimental designs are of this type.
Initiated before or at design concept finalization
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
No -- only if the process is also capable.

39. Affinity Diagrams
No -- if it is not the same - it can only be worse!
Organize ideas into meaningful categories by recognizing their underlying similarity
Used to create frequency distribution tally sheets
3.4 (assuming 1.5 sigma shift in the mean)

40. Which type of SPC measurement is more precise - variable or attribute?
No -- the variation also has to be random and "expected."
Variable.
Studying firms with the best performance in a particular area.
X-bar-bar

41. How does Juran define quality?
Pleasing to the senses.
False - because each machine will have different natural tolerances.
Fitness for use.
Defects Per Million Opportunities

42. In a Z table - what is Z?
The number of standard deviations some value is from the mean.
Actual drawings - layouts - maps - etc which show where a defect occurs
Concluding there has been an effect/change when there has not.
A tool that shows the physical flows through a space.

43. What percentage of a normal distribution lies above the mean?
Causes that lead to a particular effect.
50%
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.

44. With Six Sigma capability - how many defects per million opportunities would you see?
3.4 (assuming 1.5 sigma shift in the mean)
Kaoru Ishikawa.
X-bar-bar
Shifts - Trends - Repeating patterns - Correlation with known events

45. What is the role of a green belt?
Not necessarily.
To be a member of a Six Sigma project team.
It's good -- but it's still out of control!
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

46. In a regression - what does the p value of F tell you?
Speed - courtesy - competence - and ease of repair.
F_alpha - df(tr) - df (error)
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).
10 for Hazardous without warning 1 for none

47. List two components of internal failure.
Before production starts
=sqrt(Σ(x-x-bar)^2)/(n-1))
Scrap - rework - retest - downtime - yield losses - disposition costs.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

48. One factor at a time (OFAT)
Before production starts
Hold all input variables constant except one. Observe the response as you vary the single input.
99.73%
Actual drawings - layouts - maps - etc which show where a defect occurs

49. Define performance quality.
The primary operating characteristics of a product.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Inventory = throughput x flow time.
95%

50. Define conformance quality.
The degree to which a product meets pre-established standards.
To do a capability study for a non-centered process.
Can't tell without a Range chart.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan