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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. Process check sheets
Used to create frequency distribution tally sheets
Supplier - input - process - output - customer.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
100%

2. A process is operating "in control." Does this mean the customer's requirements are met?
Prevention - appraisal - internal failure - external failure.
Walter A. Shewhart
No -- only if the process is also capable.
Concluding there has been an effect/change when there has not.

3. What is the role of a master black belt?
The target number of standard deviations from the mean for specifications.
To mentor/coach (and sometimes train) black belts.
Deming.
Critical to quality.

4. DFMEA
The gap between specifications and how service is performed.
Fractional factorial designs (orthogonal arrays)
Initiated before or at design concept finalization
F_alpha - df(tr) - df (error)

5. What does the abbreviation UCL stand for?
To obtain a certain desirable outcome from the process
Pleasing to the senses.
The target number of standard deviations from the mean for specifications.
Upper control limit.

6. If a Cp shows that a process is not capable - should you calculate Cpk?
No -- the variation also has to be random and "expected."
No -- if it is not the same - it can only be worse!
Stratify a particular defect type according to logical criteria
Fishbone - cause-and-effect diagram.

7. What is Value Stream Mapping?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Method developed by Ishikawa to graphically display the causes of any given problem
A tool that shows where there is waste in a process.
Upper control limit.

8. Based on what principal can we use the normal distribution assumptions for SPC?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Because the mean and standard deviation are independent of each other.
Prevention - appraisal - internal failure - external failure.
Central Limit Theorem

9. Residual
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Sort - Set in Order - Shine - Standardize - Sustain
Define - measure - analyze - design - verify.
Attribute

10. What is the formula for the standard deviation of a proportion?
Concluding there has not been an effect/change when there has.
=sqrt((p*(1-p)/n)
Lower control limit.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

11. What is Type 1 Error?
The ratio of outputs to inputs; 1-scrap.
Concluding there has been an effect/change when there has not.
Is what induces the failure
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

12. What quality tool formally incorporates the voice of the customer?
QFD
Because the mean and standard deviation are independent of each other.
The House of Quality.
Upper control limit.

13. What is a CAVE man?
68%
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Fractional factorial designs (orthogonal arrays)
Someone who is consistently against virtually everything.

14. What is Jidoka?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The Japanese national quality award.
Controlling quality at the source.
X-bar-bar

15. Name the structure associated with Quality Function Deployment.
The House of Quality.
Financial - customer - internal process - innovation and learning.
99.73%
100%

16. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Workers - machines - materials.
To monitor a process when measurement by attribute is used.
Technical quality is the "what" of the service; functional quality is the "how."
Attribute

17. What percentage of a normal distribution lies above the mean?
Sort - Set in Order - Shine - Standardize - Sustain
Shows the temporal flow of activities in a project network.
50%
Defects Per Million Opportunities

18. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
To mentor/coach (and sometimes train) black belts.
Different types of defects are listed (used for Pareto chart)
Prevention and appraisal costs are balanced against internal and external failure.

19. Failure effect
Is the consequence of the failure.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Organize ideas into meaningful categories by recognizing their underlying similarity

20. What is written on the "spines" of a fishbone diagram?
Lower control limit.
Causes that lead to a particular effect.
Mean time to failure.
False - because each machine will have different natural tolerances.

21. In the Service Quality Gap Model - what is Gap 4?
The gap between what is promised and what is delivered.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Lean is waste reduction - Six Sigma is variation reduction.

22. Affinity Diagrams
Actual drawings - layouts - maps - etc which show where a defect occurs
Organize ideas into meaningful categories by recognizing their underlying similarity
Studying firms with the best performance in a particular area.
The gap between specifications and how service is performed.

23. Cause and Effect Diagrams
The gap between what management thinks customers want and the process specifications.
Central Limit Theorem
Someone who is consistently against virtually everything.
Method developed by Ishikawa to graphically display the causes of any given problem

24. When is Cpk used?
To do a capability study for a non-centered process.
A diagram that shows the relationships between activities in a project network.
QFD
Upper control limit.

25. What is Type II Error?
Sort - Set in Order - Shine - Standardize - Sustain
Concluding there has not been an effect/change when there has.
Someone who is consistently against virtually everything.
X-bar-bar

26. For what is a p-chart used?
Controlling quality at the source.
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).
Fewer good units to sell - increased variable cost/unit.

27. Uses of regression
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Variable.
A diagram that shows the relationships between activities in a project network.
A descending order-sorted bar chart with a cumulative percentage line.

28. Why do you need two control charts for variables SPC?
Studying firms with the best performance in a particular area.
Because the mean and standard deviation are independent of each other.
Is what induces the failure
Financial - customer - internal process - innovation and learning.

29. If you can only collect categorical data - what type of SPC charting can you do?
p-bar - the long-run percent defective.
Variable.
Attribute.
Producer risk.

30. For what is an x-bar chart used?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Mean time to replacement.
To monitor a process when measurement by variables is used.

31. Define durability.
QFD
Conformance to specifications.
Mean time to replacement.
Shifts - Trends - Repeating patterns - Correlation with known events

32. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Lower skill requirements - faster - less chance for error.
Fishbone - cause-and-effect diagram.
Hold all input variables constant except one. Observe the response as you vary the single input.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

33. If a three-stage process has 90% yields at each stage - what is the overall yield?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Lean (or JIT).
The US national quality award.
0.9^3 or 72.9%

34. 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
Producer risk.
A random variable that summarizes the information from the sample(s).
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:

35. Who first studied randomness in industrial processes
False - because each machine will have different natural tolerances.
Walter A. Shewhart
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
To manage the Six Sigma project.

36. Test for Independence
Not necessarily.
Upper control limit.
Rapid improvement 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

37. What is CTQ?
Critical to quality.
The primary operating characteristics of a product.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Waste.

38. What is FMEA?
The degree to which a product meets pre-established standards.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Mean time to failure.
Failure Modes and Effects Analysis

39. You have been plotting sample means on an x-bar chart and all points indicate normal - expected variation. Is the process in control?

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40. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Scrap - rework - retest - downtime - yield losses - disposition costs.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
95%

41. List two components of prevention cost.
False - because each machine will have different natural tolerances.
Prevention and appraisal costs are balanced against internal and external failure.
The US national quality award.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

42. In the Service Quality Gap Model - what is Gap 1?
The gap between what management thinks customers want and what customers really want.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Producer risk.
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

43. Presence of interaction effect
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The degree to which a product meets pre-established standards.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Because the mean and standard deviation are independent of each other.

44. Affinity Diagrams
A diagram that shows the relationships between activities in a project network.
Lower skill requirements - faster - less chance for error.
100%
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

45. Stratified defect check sheets
Stratify a particular defect type according to logical criteria
Blame.
Prevention and appraisal costs are balanced against internal and external failure.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

46. What do you do when a process is out of control?
Concluding there has not been an effect/change when there has.
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
False - because each machine will have different natural tolerances.
Look for the assignable cause of non-random variation.

47. What are the four categories of costs in Juran's framework?
Shifts - Trends - Repeating patterns - Correlation with known events
Linearity - normality - homoscedasticity - independence.
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
Prevention - appraisal - internal failure - external failure.

48. Failure Mode
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The gap between specifications and how service is performed.
Is the way in which the failure is manifested.

49. What size should samples be for attribute SPC?
Large enough to find two of the attribute - on average.
Attribute.
The degree to which a product meets pre-established standards.
Financial - customer - internal process - innovation and learning.

50. What does Crosby say about benchmarking?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
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
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
50%