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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. Define durability.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Deming.
A tool that shows performance along key dimensions all at once.
Mean time to replacement.

2. What is Type 1 Error?
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
3.4 (assuming 1.5 sigma shift in the mean)
Concluding there has been an effect/change when there has not.
Concluding there has not been an effect/change when there has.

3. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
The manager in charge of a process being improved in a Six Sigma project.
Lower control limit.
Conformance to specifications.
To monitor a process when measurement by attribute is used.

4. List two components of internal failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Before production starts
Define - measure - analyze - improve - control.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

5. Process occurance ranking
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Can't tell without a Range chart.
The ratio of outputs to inputs; 1-scrap.
Consumer risk.

6. Defect check sheets
The cycle time required to meet demand.
Before production starts
Different types of defects are listed (used for Pareto chart)
Variable.

7. Regression
Represents the behavior of a process
Scrap - rework - retest - downtime - yield losses - disposition costs.
To mentor/coach (and sometimes train) black belts.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

8. What is a CAVE man?
Someone who is consistently against virtually everything.
Large enough to find two of the attribute - on average.
To be a member of a Six Sigma project team.
Look for the assignable cause of non-random variation.

9. What is a Gantt chart?
A scatterplot.
To obtain a certain desirable outcome from the process
The number of standard deviations some value is from the mean.
Shows the temporal flow of activities in a project network.

10. Define product reliability.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
= yij - y(bar)i --> value minus sum of that treatment (of row)
Mean time to failure.

11. Why do you need two control charts for variables SPC?
Hold all input variables constant except one. Observe the response as you vary the single input.
To monitor a process when measurement by attribute is used.
Is the way in which the failure is manifested.
Because the mean and standard deviation are independent of each other.

12. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
Stratify a particular defect type according to logical criteria
The Japanese national quality award.
A tool that shows the physical flows through a space.

13. What are the three main categories of assignable cause?
The degree to which a product meets pre-established standards.
Workers - machines - materials.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Inventory = throughput x flow time.

14. A process is operating "in control." Does this mean the customer's requirements are met?
=sqrt(Σ(x-x-bar)^2)/(n-1))
No -- only if the process is also capable.
A tool that shows where there is waste in a process.
A scatterplot.

15. In a Z table - what is Z?
The number of standard deviations some value is from the mean.
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.
= yij - y(bar)i --> value minus sum of that treatment (of row)
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

16. DOE
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Is what induces the failure
The cycle time required to meet demand.

17. Advantages of DOE
99.73%
To manage the Six Sigma project.
100%
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

18. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
99.73%
The primary operating characteristics of a product.
Workers - machines - materials.
A time series plot.

19. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
The House of Quality.
95%
It looks to minimize the probability of a failure - or to minimize its effects

20. What is the Baldrige Award?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
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 US national quality award.

21. In the Service Quality Gap Model - what is Gap 5?
The gap between what customers expect and the service they receive.
99.73%
The House of Quality.
A diagram that shows the relationships between activities in a project network.

22. List two appraisal costs.
A brainstorming tool that shows the connections between ideas.
Used to create frequency distribution tally sheets
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
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

23. What does the abbreviation LCL stand for?
The House of Quality.
Lower control limit.
= 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
Actual drawings - layouts - maps - etc which show where a defect occurs

24. What is the formula for standard deviation?
Because the mean and standard deviation are independent of each other.
Workers - machines - materials.
= yij - y(bar)i --> value minus sum of that treatment (of row)
=sqrt(Σ(x-x-bar)^2)/(n-1))

25. Test for Independence
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
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
To do a capability study for a non-centered process.
= 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

26. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
The primary operating characteristics of a product.
68%
The gap between what management thinks customers want and the process specifications.
Critical to quality.

27. TWO-DIMENTIONAL SCATTER PLOT
Producer risk.
Is the consequence of the failure.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Fewer good units to sell - increased variable cost/unit.

28. What is a histogram?
Variable.
X-bar-bar
A tool that shows where there is waste in a process.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

29. Which type of SPC measurement is more precise - variable or attribute?
Variable.
What the value of the dependent variable is when the independent variable is zero.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
=sqrt((p*(1-p)/n)

30. How are LQL and AQL determined in an acceptance sampling plan?
10 for Hazardous without warning 1 for none
Walter A. Shewhart
Through producer/consumer negotiation.
The gap between specifications and how service is performed.

31. Creating a Run Chart
Conformance to specifications.
F_alpha - df(tr) - df (error)
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

32. What percentage of a normal distribution lies above the mean?
50%
The degree to which a product meets pre-established standards.
Used to create frequency distribution tally sheets
To monitor a process when measurement by attribute is used.

33. Test for constant variance
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.
Conformance to specifications.
= 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
Inventory = throughput x flow time.

34. What is process capability?
Method developed by Ishikawa to graphically display the causes of any given problem
The ability of a process to consistently meet customer specifications.
Lean is waste reduction - Six Sigma is variation reduction.
= 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

35. What is Type II Error?
p-bar - the long-run percent defective.
The primary operating characteristics of a product.
A time series plot.
Concluding there has not been an effect/change when there has.

36. Presence of interaction effect
Define - measure - analyze - design - verify.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
The House of Quality.
A scatterplot.

37. Process check sheets
A random variable that summarizes the information from the sample(s).
Hold all input variables constant except one. Observe the response as you vary the single input.
Used to create frequency distribution tally sheets
Fitness for use.

38. What is the difference between the way sampling is done for SPC and for acceptance sampling?
10 if Almost impossible to detect
Sampling for SPC is done real time.
Concluding there has not been an effect/change when there has.
To be a member of a Six Sigma project team.

39. In a regression - what does the p value of F tell you?
The secondary characteristics of a product; "bells and whistles."
5%
A tool that shows where there is waste in a process.
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).

40. Define takt time.
99.73%
Used to create frequency distribution tally sheets
The cycle time required to meet demand.
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

41. Defect location check sheets
Actual drawings - layouts - maps - etc which show where a defect occurs
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

42. What is muda
Used to create frequency distribution tally sheets
A time series plot.
Waste.
It looks to minimize the probability of a failure - or to minimize its effects

43. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Failure Modes and Effects Analysis
Variable.
Deming.
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

44. 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.
Technical quality is the "what" of the service; functional quality is the "how."
Mean time to failure.

45. Define conformance quality.
Speed - courtesy - competence - and ease of repair.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Financial - customer - internal process - innovation and learning.
The degree to which a product meets pre-established standards.

46. Manual Test for Nomality
=sqrt((p*(1-p)/n)
It looks to minimize the probability of a failure - or to minimize its effects
Kaoru Ishikawa.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

47. What is Value Stream Mapping?
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 tool that shows where there is waste in a process.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Rapid improvement process.

48. What does Crosby say about benchmarking?
A tool that shows performance along key dimensions all at once.
p-bar - the long-run percent defective.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

49. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Prevention and appraisal costs are balanced against internal and 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
Linearity - normality - homoscedasticity - independence.
Mean time to replacement.

50. In the Service Quality Gap Model - what is Gap 1?
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.
Someone who is consistently against virtually everything.
Consumer risk.