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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. Presence of interaction effect
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Fishbone - cause-and-effect diagram.

2. Disadvantages of DOE

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3. What does the abbreviation UCL stand for?
Financial - customer - internal process - innovation and learning.
Failure Modes and Effects Analysis
Upper control limit.
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

4. What is a spaghetti diagram?
A random variable that summarizes the information from the sample(s).
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
A tool that shows the physical flows through a space.
The ratio of outputs to inputs; 1-scrap.

5. Explain the difference between technical and functional service quality.
False - because each machine will have different natural tolerances.
Different types of defects are listed (used for Pareto chart)
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Technical quality is the "what" of the service; functional quality is the "how."

6. What is FMEA?
Rapid improvement process.
10 for Hazardous without warning 1 for none
A tool that shows where there is waste in a process.
Failure Modes and Effects Analysis

7. What is poka yoke?
p-bar - the long-run percent defective.
Mistake-proofing.
F_alpha - df(tr) - df (error)
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

8. If a three-stage process has 90% yields at each stage - what is the overall yield?
Fitness for use.
0.9^3 or 72.9%
The number of standard deviations some value is from the mean.
Workers - machines - materials.

9. Pareto Analysis
A diagram that shows the relationships between activities in a project network.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The gap between what customers expect and the service they receive.
Fewer good units to sell - increased variable cost/unit.

10. One factor at a time (OFAT)
Organize ideas into meaningful categories by recognizing their underlying similarity
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Concluding there has not been an effect/change when there has.
Hold all input variables constant except one. Observe the response as you vary the single input.

11. What is an affinity diagram?
To mentor/coach (and sometimes train) black belts.
A brainstorming tool that shows the connections between ideas.
A diagram that shows the relationships between activities in a project network.
The gap between what is promised and what is delivered.

12. In a regression - what does the standard error of the estimate tell you?
Concluding there has been an effect/change when there has not.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Lean (or JIT).
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

13. Detection Criteria Ranking
Kaoru Ishikawa.
To obtain a certain desirable outcome from the process
10 if Almost impossible to detect
99.73%

14. Affinity Diagrams
Is the way in which the failure is manifested.
The gap between what management thinks customers want and what customers really want.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
To do a capability study for a non-centered process.

15. Define conformance quality.
The degree to which a product meets pre-established standards.
Rapid improvement process.
To monitor a process when measurement by attribute is used.
To manage the Six Sigma project.

16. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
Lean is waste reduction - Six Sigma is variation reduction.
Financial - customer - internal process - innovation and learning.
50%

17. What are the three main categories of assignable cause?
Waste.
Workers - machines - materials.
The ability of a process to consistently meet customer specifications.
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

18. Design of Experiments (DOE) approach
Mean time to replacement.
Assigns scores to weighted criteria for each project under consideration.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Before production starts

19. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Workers - machines - materials.
Conformance to specifications.
99.73%
Define - measure - analyze - design - verify.

20. What is a Pareto chart?
Variable.
Consumer risk.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
A descending order-sorted bar chart with a cumulative percentage line.

21. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Actual drawings - layouts - maps - etc which show where a defect occurs
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 gap between what is promised and what is delivered.
No -- the variation also has to be random and "expected."

22. F value
F_alpha - df(tr) - df (error)
Someone who is consistently against virtually everything.
=sqrt(Σ(x-x-bar)^2)/(n-1))
A tool that shows where there is waste in a process.

23. Residual
The House of Quality.
Studying firms with the best performance in a particular area.
F_alpha - df(tr) - df (error)
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

24. What are the four categories of costs in Juran's framework?
A brainstorming tool that shows the connections between ideas.
Prevention - appraisal - internal failure - external failure.
Linearity - normality - homoscedasticity - independence.
Because the mean and standard deviation are independent of each other.

25. What is Type II Error?
Concluding there has not been an effect/change when there has.
Fractional factorial designs (orthogonal arrays)
Prevention - appraisal - internal failure - external failure.
Attribute.

26. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Define - measure - analyze - design - verify.
Lean (or JIT).
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
Is the consequence of the failure.

27. PFMEA
A brainstorming tool that shows the connections between ideas.
The secondary characteristics of a product; "bells and whistles."
Workers - machines - materials.
Before production starts

28. What is CTQ?
Critical to quality.
A diagram that shows the relationships between activities in a project network.
The target number of standard deviations from the mean for specifications.
Define - measure - analyze - design - verify.

29. With Six Sigma capability - how many defects per million opportunities would you see?
To obtain a certain desirable outcome from the process
Defects Per Million Opportunities
X-bar-bar
3.4 (assuming 1.5 sigma shift in the mean)

30. Failure cause
A brainstorming tool that shows the connections between ideas.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Is what induces the failure
Mistake-proofing.

31. For what is an x-bar chart used?
Through producer/consumer negotiation.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
To monitor a process when measurement by variables is used.
It's good -- but it's still out of control!

32. For what is a p-chart used?
Is the consequence of the failure.
95%
Someone who is consistently against virtually everything.
To monitor a process when measurement by attribute is used.

33. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Attribute
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
The gap between what management thinks customers want and what customers really want.
Not necessarily.

34. TWO-DIMENTIONAL SCATTER PLOT
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Fractional factorial designs (orthogonal arrays)
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
To do a capability study for a non-centered process.

35. What is process capability?
The ability of a process to consistently meet customer specifications.
A random variable that summarizes the information from the sample(s).
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 gap between specifications and how service is performed.

36. In the Service Quality Gap Model - what is Gap 3?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
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 gap between specifications and how service is performed.

37. Statistical Hypothesis
To manage the Six Sigma project.
An assertion or conjecture concerning one or more populations
Prevention and appraisal costs are balanced against internal and external failure.
Technical quality is the "what" of the service; functional quality is the "how."

38. One factor at a time (OFAT)
Shows the temporal flow of activities in a project network.
To obtain a certain desirable outcome from the process
Consumer risk.
Observed variation in response is caused by the input

39. Define yield.
Sampling for SPC is done real time.
The degree to which a product meets pre-established standards.
Fitness for use.
The ratio of outputs to inputs; 1-scrap.

40. There are two milling machines in the shop. Data has been collected on one to compute control limits for both. This is acceptable SPC practice - true or false and why?
=sqrt((p*(1-p)/n)
False - because each machine will have different natural tolerances.
Technical quality is the "what" of the service; functional quality is the "how."
Taguchi

41. Regression
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).
= yij - y(bar)i --> value minus sum of that treatment (of row)
Represents the behavior of a process
Blame.

42. What is the formula for the standard deviation of a proportion?
Outside.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
=sqrt((p*(1-p)/n)
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

43. What is the center line of an X-bar chart?
The degree to which a product meets pre-established standards.
X-bar-bar
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
Look for the assignable cause of non-random variation.

44. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Outside.
Observed variation in response is caused by the input
= yij - y(bar)i --> value minus sum of that treatment (of row)
The degree to which a product meets pre-established standards.

45. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
95%
The ratio of outputs to inputs; 1-scrap.
Speed - courtesy - competence - and ease of repair.
It's good -- but it's still out of control!

46. When yields decrease - what are the two effects on contribution?
Fewer good units to sell - increased variable cost/unit.
Brand image.
They move closer to the center line.
Conformance to specifications.

47. List two components of prevention cost.
A tool that shows performance along key dimensions all at once.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
The target number of standard deviations from the mean for specifications.
The manager in charge of a process being improved in a Six Sigma project.

48. List two appraisal costs.
Prevention - appraisal - internal failure - external failure.
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
5%
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

49. What graphical tool is used to show the relationship between two numerical variables?
Brand image.
10 if Almost impossible to detect
Mistake-proofing.
A scatterplot.

50. Define perceived quality (Garvin's framework).
Brand image.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
False - because each machine will have different natural tolerances.
Actual drawings - layouts - maps - etc which show where a defect occurs