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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 your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
A brainstorming tool that shows the connections between ideas.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Variable.
The ability of a process to consistently meet customer specifications.

2. Defect location check sheets
No -- if it is not the same - it can only be worse!
X-bar-bar
Kaoru Ishikawa.
Actual drawings - layouts - maps - etc which show where a defect occurs

3. Complete this quality phrase: 'Fix the process - not the _____.'
Lower control limit.
Blame.
The gap between what management thinks customers want and what customers really want.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

4. Your production process meets customer specifications. Is your process in control?
No -- the variation also has to be random and "expected."
Attribute
Not necessarily.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

5. What is the role of a black belt?
=sqrt(Σ(x-x-bar)^2)/(n-1))
To manage the Six Sigma project.
A time series plot.
Shifts - Trends - Repeating patterns - Correlation with known events

6. In a regression - what does the coefficient of the intercept tell you
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.
What the value of the dependent variable is when the independent variable is zero.
The gap between what is promised and what is delivered.
To do a capability study for a non-centered process.

7. What is a histogram?
To manage the Six Sigma project.
50%
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Variable.

8. Define product reliability.
Fishbone - cause-and-effect diagram.
Mean time to failure.
Define - measure - analyze - design - verify.
Consumer risk.

9. One factor at a time (OFAT)
Observed variation in response is caused by the input
The degree to which a product meets pre-established standards.
Is the way in which the failure is manifested.
Deming.

10. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Before production starts
Fractional factorial designs (orthogonal arrays)
Variable.
No -- the variation also has to be random and "expected."

11. What is the formula for standard deviation?
Used to create frequency distribution tally sheets
To mentor/coach (and sometimes train) black belts.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Method developed by Ishikawa to graphically display the causes of any given problem

12. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Workers - machines - materials.
99.73%
Mistake-proofing.
The US national quality award.

13. What is DMADV?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Actual drawings - layouts - maps - etc which show where a defect occurs
Define - measure - analyze - design - verify.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

14. Affinity Diagrams
Sampling for SPC is done real time.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
They move closer to the center line.
The cycle time required to meet demand.

15. What is a Pareto chart?
No -- only if the process is also capable.
Linearity - normality - homoscedasticity - independence.
A descending order-sorted bar chart with a cumulative percentage line.
Mistake-proofing.

16. Failure effect
Mean time to failure.
Is the consequence of the failure.
Waste.
Taguchi

17. List two appraisal costs.
What the value of the dependent variable is when the independent variable is zero.
To be a member of a Six Sigma project team.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
No -- only if the process is also capable.

18. In Juran's Cost of Quality model - which categories of costs balance which other categories?
The House of Quality.
Prevention and appraisal costs are balanced against internal and external failure.
Attribute.
The US national quality award.

19. Which type of SPC measurement is more precise - variable or attribute?
The secondary characteristics of a product; "bells and whistles."
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
Is what induces the failure
Variable.

20. Uses of regression - Control
To obtain a certain desirable outcome from the process
Observed variation in response is caused by the input
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Is the way in which the failure is manifested.

21. What quality tool formally incorporates the voice of the customer?
Lean is waste reduction - Six Sigma is variation reduction.
Central Limit Theorem
Prevention - appraisal - internal failure - external failure.
QFD

22. Define benchmarking.
Fitness for use.
Variable.
Outside.
Studying firms with the best performance in a particular area.

23. What is a dashboard?
A tool that shows performance along key dimensions all at once.
The manager in charge of a process being improved in a Six Sigma project.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
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:

24. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
Is the consequence of the failure.
An assertion or conjecture concerning one or more populations
Through producer/consumer negotiation.

25. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
10 for Hazardous without warning 1 for none
Brand image.
5%
It's good -- but it's still out of control!

26. A process is operating "in control." Does this mean the customer's requirements are met?
The manager in charge of a process being improved in a Six Sigma project.
Concluding there has not been an effect/change when there has.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
No -- only if the process is also capable.

27. What does a project prioritization matrix do?
Assigns scores to weighted criteria for each project under consideration.
Is the consequence of the failure.
Lean is waste reduction - Six Sigma is variation reduction.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

28. Regression
99.73%
Pleasing to the senses.
A random variable that summarizes the information from the sample(s).
Represents the behavior of a process

29. What is the center line of a p-chart?
Mean time to replacement.
Mean time to failure.
p-bar - the long-run percent defective.
No -- if it is not the same - it can only be worse!

30. What is an affinity diagram?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Walter A. Shewhart
A brainstorming tool that shows the connections between ideas.
To do a capability study for a non-centered process.

31. What graphical tool is used to show the relationship between two numerical variables?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
To be a member of a Six Sigma project team.
A scatterplot.
Supplier - input - process - output - customer.

32. Stratified defect check sheets
Stratify a particular defect type according to logical criteria
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
No -- the variation also has to be random and "expected."

33. What is a spaghetti diagram?
Variable.
A tool that shows the physical flows through a space.
The gap between specifications and how service is performed.
The primary operating characteristics of a product.

34. In a regression - what does R-square tell you?
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).
Because the mean and standard deviation are independent of each other.
= yij - y(bar)i --> value minus sum of that treatment (of row)

35. What is Little's Law?
Pleasing to the senses.
Deming.
Inventory = throughput x flow time.
The number of standard deviations some value is from the mean.

36. What is Type 1 Error?
Is the way in which the failure is manifested.
The target number of standard deviations from the mean for specifications.
Concluding there has been an effect/change when there has not.
To obtain a certain desirable outcome from the process

37. What is a network diagram?
Outside.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
A diagram that shows the relationships between activities in a project network.

38. What are the four perspectives of the Balanced Scorecard?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
The ratio of outputs to inputs; 1-scrap.
Financial - customer - internal process - innovation and learning.
Assigns scores to weighted criteria for each project under consideration.

39. Regression Analysis
Someone who is consistently against virtually everything.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Sampling for SPC is done real time.
A tool that shows the physical flows through a space.

40. To what does the Six in Six Sigma relate?
Fishbone - cause-and-effect diagram.
The target number of standard deviations from the mean for specifications.
The gap between specifications and how service is performed.
Kaoru Ishikawa.

41. The data points on an SPC p-chart of defective percent plot below the mean. Is this good or bad?

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42. What does Crosby say about benchmarking?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
The gap between what management thinks customers want and what customers really want.
What the value of the dependent variable is when the independent variable is zero.
Shifts - Trends - Repeating patterns - Correlation with known events

43. DFMEA
Initiated before or at design concept finalization
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Organize ideas into meaningful categories by recognizing their underlying similarity
Speed - courtesy - competence - and ease of repair.

44. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Shifts - Trends - Repeating patterns - Correlation with known events
Lower skill requirements - faster - less chance for error.

45. Taguchi's experimental designs are of this type.
50%
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.
Fractional factorial designs (orthogonal arrays)
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

46. What size should samples be for attribute SPC?
Speed - courtesy - competence - and ease of repair.
Large enough to find two of the attribute - on average.
A tool that shows where there is waste in a process.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

47. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Sort - Set in Order - Shine - Standardize - Sustain
Mean time to replacement.
Attribute
Waste.

48. Design of Experiments (DOE) approach
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
The US national quality award.
A random variable that summarizes the information from the sample(s).

49. Define aesthetic quality.
Pleasing to the senses.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
To obtain a certain desirable outcome from the process
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

50. Advantages of DOE
Defects Per Million Opportunities
The ability of a process to consistently meet customer specifications.
Can't tell without a Range chart.
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

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