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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
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Stratify a particular defect type according to logical criteria

2. Who first studied randomness in industrial processes
Prevention - appraisal - internal failure - external failure.
Lower control limit.
Observed variation in response is caused by the input
Walter A. Shewhart

3. If you can only collect categorical data - what type of SPC charting can you do?
No -- if it is not the same - it can only be worse!
The manager in charge of a process being improved in a Six Sigma project.
Attribute.
Can't tell without a Range chart.

4. If a three-stage process has 90% yields at each stage - what is the overall yield?
0.9^3 or 72.9%
The ratio of outputs to inputs; 1-scrap.
F_alpha - df(tr) - df (error)
Method developed by Ishikawa to graphically display the causes of any given problem

5. In a regression - what does the standard error of the estimate tell you?
To do a capability study for a non-centered process.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Upper control limit.

6. How are LQL and AQL determined in an acceptance sampling plan?
100%
Defects Per Million Opportunities
Through producer/consumer negotiation.
Not necessarily.

7. What size should samples be for attribute SPC?
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
Large enough to find two of the attribute - on average.
The gap between specifications and how service is performed.
Mean time to failure.

8. What is written on the "spines" of a fishbone diagram?
The US national quality award.
Not necessarily.
Causes that lead to a particular effect.
Different types of defects are listed (used for Pareto chart)

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

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10. What is the role of a black belt?
Producer risk.
Represents the behavior of a process
To manage the Six Sigma project.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

11. What graphical tool is used to show the relationship between two numerical variables?
50%
Before production starts
Deming.
A scatterplot.

12. Process occurance ranking
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The primary operating characteristics of a product.
Workers - machines - materials.
To mentor/coach (and sometimes train) black belts.

13. What is the 5S model?
Defects Per Million Opportunities
X-bar-bar
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
3.4 (assuming 1.5 sigma shift in the mean)

14. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Fishbone - cause-and-effect diagram.
The degree to which a product meets pre-established standards.
Prevention and appraisal costs are balanced against internal and external failure.
The gap between what is promised and what is delivered.

15. Residual
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Fitness for use.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

16. Uses of regression - Control
To obtain a certain desirable outcome from the process
Inventory = throughput x flow time.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
A diagram that shows the relationships between activities in a project network.

17. What percentage of a normal distribution lies above the mean?
The gap between what management thinks customers want and what customers really want.
50%
Concluding there has not been an effect/change when there has.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

18. One factor at a time (OFAT)
Observed variation in response is caused by the input
Blame.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

19. In a regression - what does R-square tell you?
Critical to quality.
Fitness for use.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

20. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
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).
A time series plot.
Is the way in which the failure is manifested.

21. In the Service Quality Gap Model - what is Gap 1?
The gap between what management thinks customers want and what customers really want.
Studying firms with the best performance in a particular area.
Taguchi
Because the mean and standard deviation are independent of each other.

22. What is DMADV?
Define - measure - analyze - design - verify.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Can't tell without a Range chart.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

23. List two components of external failure.
The degree to which a product meets pre-established standards.
A random variable that summarizes the information from the sample(s).
Kaoru Ishikawa.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

24. DFMEA
No -- the variation also has to be random and "expected."
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Failure Modes and Effects Analysis
Initiated before or at design concept finalization

25. What is a network diagram?
Prevention - appraisal - internal failure - external failure.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Outside.
A diagram that shows the relationships between activities in a project network.

26. TWO-DIMENTIONAL SCATTER PLOT
Waste.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Upper control limit.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

27. What does the abbreviation LCL stand for?
Brand image.
A diagram that shows the relationships between activities in a project network.
To be a member of a Six Sigma project team.
Lower control limit.

28. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Kaoru Ishikawa.
QFD
99.73%
The cycle time required to meet demand.

29. What is the center line of a p-chart?
p-bar - the long-run percent defective.
A random variable that summarizes the information from the sample(s).
Attribute.
Prevention - appraisal - internal failure - external failure.

30. Complete this quality phrase: 'Fix the process - not the _____.'
Blame.
Lower skill requirements - faster - less chance for error.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The secondary characteristics of a product; "bells and whistles."

31. What is CTQ?
Critical to quality.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Mean time to failure.
Shifts - Trends - Repeating patterns - Correlation with known events

32. What are two other names for an Ishikawa diagram?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
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.
Stratify a particular defect type according to logical criteria

33. What type of risk is associated with Type 1 Error?
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
Lean is waste reduction - Six Sigma is variation reduction.
Producer risk.
The secondary characteristics of a product; "bells and whistles."

34. Cause and Effect Diagrams
Mean time to failure.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
No -- the variation also has to be random and "expected."
Method developed by Ishikawa to graphically display the causes of any given problem

35. Regression Analysis
Method developed by Ishikawa to graphically display the causes of any given problem
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
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
Pleasing to the senses.

36. Taguchi's experimental designs are of this type.
The gap between what management thinks customers want and the process specifications.
Fractional factorial designs (orthogonal arrays)
100%
The US national quality award.

37. What does a project prioritization matrix do?
Assigns scores to weighted criteria for each project under consideration.
F_alpha - df(tr) - df (error)
Is the consequence of the failure.
Linearity - normality - homoscedasticity - independence.

38. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
The cycle time required to meet demand.
To mentor/coach (and sometimes train) black belts.
Failure Modes and Effects Analysis

39. Your production process meets customer specifications. Is your process in control?
Not necessarily.
5%
The manager in charge of a process being improved in a Six Sigma project.
Central Limit Theorem

40. The Test Statistic (TS)
A random variable that summarizes the information from the sample(s).
100%
Shows the temporal flow of activities in a project network.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

41. What is DPMO?
10 for Hazardous without warning 1 for none
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
Mistake-proofing.
Defects Per Million Opportunities

42. In the Service Quality Gap Model - what is Gap 3?
Causes that lead to a particular effect.
The gap between specifications and how service is performed.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
F_alpha - df(tr) - df (error)

43. Histogram by Hand
QFD
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
Deming.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

44. What is the Deming Prize?
Lean (or JIT).
The Japanese national quality award.
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).
Shows the temporal flow of activities in a project network.

45. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
The target number of standard deviations from the mean for specifications.
Sort - Set in Order - Shine - Standardize - Sustain
Concluding there has not been an effect/change when there has.

46. F value
3.4 (assuming 1.5 sigma shift in the mean)
F_alpha - df(tr) - df (error)
Central Limit Theorem
Variable.

47. What are the four regression assumptions?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Linearity - normality - homoscedasticity - independence.
10 for Hazardous without warning 1 for none
Lean is waste reduction - Six Sigma is variation reduction.

48. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
QFD
Attribute
Different types of defects are listed (used for Pareto chart)

49. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Lean (or JIT).
Assigns scores to weighted criteria for each project under consideration.
Concluding there has been an effect/change when there has not.

50. In the Service Quality Gap Model - what is Gap 4?
It looks to minimize the probability of a failure - or to minimize its effects
Stratify a particular defect type according to logical criteria
The gap between what is promised and what is delivered.
The target number of standard deviations from the mean for specifications.