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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. If a Cp shows that a process is not capable - should you calculate Cpk?
Look for the assignable cause of non-random variation.
No -- if it is not the same - it can only be worse!
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
A tool that shows performance along key dimensions all at once.

2. Process occurance ranking
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Fitness for use.
Consumer risk.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

3. Regression
Represents the behavior of a process
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Can't tell without a Range chart.
Is what induces the failure

4. Process check sheets
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
It's good -- but it's still out of control!
Used to create frequency distribution tally sheets
Workers - machines - materials.

5. Detection Criteria Ranking
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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
10 if Almost impossible to detect

6. Define takt time.
The gap between specifications and how service is performed.
The cycle time required to meet demand.
=sqrt((p*(1-p)/n)
Outside.

7. DOE
Method developed by Ishikawa to graphically display the causes of any given problem
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 simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Before production starts

8. Define product reliability.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Organize ideas into meaningful categories by recognizing their underlying similarity
Prevention - appraisal - internal failure - external failure.
Mean time to failure.

9. What is Type II Error?
Concluding there has not been an effect/change when there has.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
A random variable that summarizes the information from the sample(s).
Lean is waste reduction - Six Sigma is variation reduction.

10. In the Service Quality Gap Model - what is Gap 3?
A tool that shows performance along key dimensions all at once.
The gap between specifications and how service is performed.
A descending order-sorted bar chart with a cumulative percentage line.
Concluding there has not been an effect/change when there has.

11. Who first studied randomness in industrial processes
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Walter A. Shewhart
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Represents the behavior of a process

12. What are the Five Dimensions of Service Quality?
The Japanese national quality award.
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
Reliability - Assurance - Responsiveness - Tangibles - Empathy
To manage the Six Sigma project.

13. Cause and Effect Diagrams
To be a member of a Six Sigma project team.
Concluding there has not been an effect/change when there has.
Method developed by Ishikawa to graphically display the causes of any given problem
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

14. Define yield.
The ratio of outputs to inputs; 1-scrap.
Lower control limit.
It usually isn't possible to hold all other variables constant - There is no way to account for the effect of joint variation of independent variables - such as interaction - There is no way to account for experimental error - including measurement v
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

15. List two components of prevention cost.
Fishbone - cause-and-effect diagram.
Fewer good units to sell - increased variable cost/unit.
Speed - courtesy - competence - and ease of repair.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

16. If you can only collect categorical data - what type of SPC charting can you do?
Attribute.
Kaoru Ishikawa.
Outside.
A time series plot.

17. Risk Priority Number RPN
A random variable that summarizes the information from the sample(s).
Attribute.
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
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

18. What is Type 1 Error?
Prevention and appraisal costs are balanced against internal and external failure.
A time series plot.
The gap between what customers expect and the service they receive.
Concluding there has been an effect/change when there has not.

19. What is a Pareto chart?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
The number of standard deviations some value is from the mean.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
A descending order-sorted bar chart with a cumulative percentage line.

20. Define aesthetic quality.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
To do a capability study for a non-centered process.
Pleasing to the senses.
p-bar - the long-run percent defective.

21. What does SIPOC stand for?
No -- if it is not the same - it can only be worse!
Sampling for SPC is done real time.
Prevention and appraisal costs are balanced against internal and external failure.
Supplier - input - process - output - customer.

22. Affinity Diagrams
Organize ideas into meaningful categories by recognizing their underlying similarity
Actual drawings - layouts - maps - etc which show where a defect occurs
Scrap - rework - retest - downtime - yield losses - disposition costs.
Upper control limit.

23. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Can't tell without a Range chart.
50%
No -- the variation also has to be random and "expected."

24. One factor at a time (OFAT)
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
It's good -- but it's still out of control!
Hold all input variables constant except one. Observe the response as you vary the single input.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

25. Define serviceability.
=sqrt((p*(1-p)/n)
Speed - courtesy - competence - and ease of repair.
Supplier - input - process - output - customer.
10 if Almost impossible to detect

26. What is the formula for standard deviation?
Taguchi
=sqrt(Σ(x-x-bar)^2)/(n-1))
Supplier - input - process - output - customer.
Central Limit Theorem

27. What is the difference between Lean and Six Sigma?
Lean is waste reduction - Six Sigma is variation reduction.
The cycle time required to meet demand.
The secondary characteristics of a product; "bells and whistles."
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:

28. FMEA
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Before production starts
The House of Quality.
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

29. What is the role of a master black belt?
To mentor/coach (and sometimes train) black belts.
10 for Hazardous without warning 1 for none
Financial - customer - internal process - innovation and learning.
The Japanese national quality award.

30. What is written on the "spines" of a fishbone diagram?
The target number of standard deviations from the mean for specifications.
Supplier - input - process - output - customer.
To obtain a certain desirable outcome from the process
Causes that lead to a particular effect.

31. Residual
Initiated before or at design concept finalization
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Supplier - input - process - output - customer.
F_alpha - df(tr) - df (error)

32. Disadvantages of DOE

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33. List two appraisal costs.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
10 if Almost impossible to detect
No -- if it is not the same - it can only be worse!
Central Limit Theorem

34. Failure effect
Is the consequence of the failure.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
They move closer to the center line.
Consumer risk.

35. In a Z table - what is Z?
To obtain a certain desirable outcome from the process
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 number of standard deviations some value is from the mean.
Concluding there has not been an effect/change when there has.

36. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Large enough to find two of the attribute - on average.
It usually isn't possible to hold all other variables constant - There is no way to account for the effect of joint variation of independent variables - such as interaction - There is no way to account for experimental error - including measurement v
To monitor a process when measurement by attribute is used.
5%

37. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Defects Per Million Opportunities
95%
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Sampling for SPC is done real time.

38. What are the four perspectives of the Balanced Scorecard?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Financial - customer - internal process - innovation and learning.
Method developed by Ishikawa to graphically display the causes of any given problem
Is what induces the failure

39. What is a Gage R&R?
X-bar-bar
They move closer to the center line.
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).
Waste.

40. What is the Deming Prize?
Sampling for SPC is done real time.
Different types of defects are listed (used for Pareto chart)
The Japanese national quality award.
Consumer risk.

41. In the Service Quality Gap Model - what is Gap 5?
The gap between what customers expect and the service they receive.
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 monitor a process when measurement by variables is used.
X-bar-bar

42. What is a network diagram?
The gap between specifications and how service is performed.
Inventory = throughput x flow time.
A diagram that shows the relationships between activities in a project network.
Someone who is consistently against virtually everything.

43. What is Little's Law?
Scrap - rework - retest - downtime - yield losses - disposition costs.
Inventory = throughput x flow time.
The ability of a process to consistently meet customer specifications.
Speed - courtesy - competence - and ease of repair.

44. What is DPMO?
F_alpha - df(tr) - df (error)
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Actual drawings - layouts - maps - etc which show where a defect occurs
Defects Per Million Opportunities

45. PFMEA
Variable.
To manage the Six Sigma project.
Before production starts
Central Limit Theorem

46. In the Service Quality Gap Model - what is Gap 4?
The gap between what is promised and what is delivered.
Variable.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
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

47. What is a CAVE man?
The gap between what customers expect and the service they receive.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Someone who is consistently against virtually everything.
100%

48. What are the four categories of costs in Juran's framework?
Look for the assignable cause of non-random variation.
Prevention - appraisal - internal failure - external failure.
Lean (or JIT).
A time series plot.

49. TWO-DIMENTIONAL SCATTER PLOT
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
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
Before production starts
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

50. What is the role of a green belt?
Because the mean and standard deviation are independent of each other.
=sqrt((p*(1-p)/n)
Deming.
To be a member of a Six Sigma project team.