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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. A process is operating "in control." Does this mean the customer's requirements are met?
No -- only if the process is also capable.
Attribute.
Causes that lead to a particular effect.
Sort - Set in Order - Shine - Standardize - Sustain

2. In the Service Quality Gap Model - what is Gap 5?
The gap between what customers expect and the service they receive.
Mean time to failure.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
A random variable that summarizes the information from the sample(s).

3. Your production process meets customer specifications. Is your process in control?
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).
Not necessarily.
Blame.

4. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
The ratio of outputs to inputs; 1-scrap.
68%
The ability of a process to consistently meet customer specifications.
Sampling for SPC is done real time.

5. How are LQL and AQL determined in an acceptance sampling plan?
Waste.
Observed variation in response is caused by the input
The US national quality award.
Through producer/consumer negotiation.

6. What are two other names for an Ishikawa diagram?
Conformance to specifications.
Fishbone - cause-and-effect diagram.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
A time series plot.

7. Who developed the fishbone diagram?
Kaoru Ishikawa.
Can't tell without a Range chart.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Different types of defects are listed (used for Pareto chart)

8. What is CTQ?
Consumer risk.
Critical to quality.
=sqrt((p*(1-p)/n)
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

9. What is muda
Waste.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Blame.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

10. Uses of regression
Because the mean and standard deviation are independent of each other.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Used to create frequency distribution tally sheets
Controlling quality at the source.

11. Non-random patterns (Run Charts)
Define - measure - analyze - improve - control.
A tool that shows performance along key dimensions all at once.
Initiated before or at design concept finalization
Shifts - Trends - Repeating patterns - Correlation with known events

12. What happens to control limits on an SPC chart when sample size is increased?
Used to create frequency distribution tally sheets
Someone who is consistently against virtually everything.
Fewer good units to sell - increased variable cost/unit.
They move closer to the center line.

13. In a regression - what does the coefficient of the intercept tell you
What the value of the dependent variable is when the independent variable is zero.
95%
Conformance to specifications.
Lean is waste reduction - Six Sigma is variation reduction.

14. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Fractional factorial designs (orthogonal arrays)
No -- if it is not the same - it can only be worse!
Conformance to specifications.
Failure Modes and Effects Analysis

15. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
3.4 (assuming 1.5 sigma shift in the mean)
Blame.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

16. Effect ranking (Severity of the Defect)
Lower control limit.
10 if Almost impossible to detect
10 for Hazardous without warning 1 for none
A tool that shows where there is waste in a process.

17. What does a project prioritization matrix do?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
68%
Assigns scores to weighted criteria for each project under consideration.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

18. ANOVA

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19. What is a CAVE man?
Not necessarily.
Is the way in which the failure is manifested.
To monitor a process when measurement by variables is used.
Someone who is consistently against virtually everything.

20. Failure cause
Controlling quality at the source.
Is what induces the failure
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
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:

21. In the Service Quality Gap Model - what is Gap 3?
QFD
Define - measure - analyze - improve - control.
The gap between specifications and how service is performed.
10 if Almost impossible to detect

22. Define benchmarking.
Prevention and appraisal costs are balanced against internal and external failure.
Studying firms with the best performance in a particular area.
X-bar-bar
Mistake-proofing.

23. For what is a p-chart used?
Lower skill requirements - faster - less chance for error.
Is what induces the failure
To monitor a process when measurement by attribute is used.
The US national quality award.

24. Failure effect
0.9^3 or 72.9%
Defects Per Million Opportunities
Speed - courtesy - competence - and ease of repair.
Is the consequence of the failure.

25. If a three-stage process has 90% yields at each stage - what is the overall yield?
Because the mean and standard deviation are independent of each other.
= 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.
0.9^3 or 72.9%

26. Process occurance ranking
Reliability - Assurance - Responsiveness - Tangibles - Empathy
False - because each machine will have different natural tolerances.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The secondary characteristics of a product; "bells and whistles."

27. Pareto Analysis
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.
Assigns scores to weighted criteria for each project under consideration.
Method developed by Ishikawa to graphically display the causes of any given problem

28. Define durability.
Mean time to replacement.
False - because each machine will have different natural tolerances.
Define - measure - analyze - improve - control.
Variable.

29. When yields decrease - what are the two effects on contribution?
p-bar - the long-run percent defective.
Used to create frequency distribution tally sheets
Fewer good units to sell - increased variable cost/unit.
No -- if it is not the same - it can only be worse!

30. Statistical Hypothesis
Shifts - Trends - Repeating patterns - Correlation with known events
An assertion or conjecture concerning one or more populations
The gap between specifications and how service is performed.
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).

31. Define features.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The secondary characteristics of a product; "bells and whistles."
Taguchi
X-bar-bar

32. Who first studied randomness in industrial processes
Taguchi
10 if Almost impossible to detect
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Walter A. Shewhart

33. Defect check sheets
Different types of defects are listed (used for Pareto chart)
Shifts - Trends - Repeating patterns - Correlation with known events
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
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

34. What is Type 1 Error?
Fractional factorial designs (orthogonal arrays)
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Concluding there has been an effect/change when there has not.
Concluding there has not been an effect/change when there has.

35. Defect location check sheets
Shifts - Trends - Repeating patterns - Correlation with known events
Fitness for use.
A tool that shows where there is waste in a process.
Actual drawings - layouts - maps - etc which show where a defect occurs

36. Uses of regression - Control
To obtain a certain desirable outcome from the process
A diagram that shows the relationships between activities in a project network.
100%
Waste.

37. What is Little's Law?
Concluding there has not been an effect/change when there has.
Inventory = throughput x flow time.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
A time series plot.

38. If you can only collect categorical data - what type of SPC charting can you do?
Method developed by Ishikawa to graphically display the causes of any given problem
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Is the way in which the failure is manifested.
Attribute.

39. What is the formula for standard deviation?
An assertion or conjecture concerning one or more populations
=sqrt(Σ(x-x-bar)^2)/(n-1))
F_alpha - df(tr) - df (error)
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:

40. List two appraisal costs.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
To obtain a certain desirable outcome from the process
Mean time to replacement.
=sqrt(Σ(x-x-bar)^2)/(n-1))

41. What is an affinity diagram?
Prevention and appraisal costs are balanced against internal and external failure.
Sampling for SPC is done real time.
A brainstorming tool that shows the connections between ideas.
Define - measure - analyze - design - verify.

42. Test for constant variance
Stratify a particular defect type according to logical criteria
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
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.
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).

43. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Consumer risk.
Controlling quality at the source.
Shows the temporal flow of activities in a project network.
Attribute

44. What is process capability?
To do a capability study for a non-centered process.
QFD
Variable.
The ability of a process to consistently meet customer specifications.

45. What does the abbreviation LCL stand for?
Lower control limit.
A random variable that summarizes the information from the sample(s).
Stratify a particular defect type according to logical criteria
Technical quality is the "what" of the service; functional quality is the "how."

46. What is Type II Error?
Deming.
Defects Per Million Opportunities
Technical quality is the "what" of the service; functional quality is the "how."
Concluding there has not been an effect/change when there has.

47. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Lean (or JIT).
Can't tell without a Range chart.
Prevention and appraisal costs are balanced against internal and external failure.
X-bar-bar

48. What percentage of a normal distribution lies above the mean?
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.
50%
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

49. What is the role of a black belt?
= yij - y(bar)i --> value minus sum of that treatment (of row)
To manage the Six Sigma project.
Speed - courtesy - competence - and ease of repair.
Rapid improvement process.

50. 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?
F_alpha - df(tr) - df (error)
It looks to minimize the probability of a failure - or to minimize its effects
The target number of standard deviations from the mean for specifications.
False - because each machine will have different natural tolerances.