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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?
No -- if it is not the same - it can only be worse!
The primary operating characteristics of a product.
Organize ideas into meaningful categories by recognizing their underlying similarity
= yij - y(bar)i --> value minus sum of that treatment (of row)

2. For what is a p-chart used?
To monitor a process when measurement by attribute is used.
Someone who is consistently against virtually everything.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Pleasing to the senses.

3. What are the four regression assumptions?
Waste.
Lean (or JIT).
Linearity - normality - homoscedasticity - independence.
Walter A. Shewhart

4. Design of Experiments (DOE) approach
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.
Shifts - Trends - Repeating patterns - Correlation with known events
Causes that lead to a particular effect.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

5. Uses of regression - Control
68%
To obtain a certain desirable outcome from the process
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
10 if Almost impossible to detect

6. What are the Five Dimensions of Service Quality?
It's good -- but it's still out of control!
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Attribute.
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

7. What is a Gage R&R?
Linearity - normality - homoscedasticity - independence.
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).
Stratify a particular defect type according to logical criteria
The Japanese national quality award.

8. Define perceived quality (Garvin's framework).
Shows the temporal flow of activities in a project network.
What the value of the dependent variable is when the independent variable is zero.
Walter A. Shewhart
Brand image.

9. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
Defects Per Million Opportunities
10 for Hazardous without warning 1 for none
= yij - y(bar)i --> value minus sum of that treatment (of row)

10. PFMEA
Inventory = throughput x flow time.
Is the consequence of the failure.
Before production starts
The primary operating characteristics of a product.

11. Who developed the fishbone diagram?
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
Prevention and appraisal costs are balanced against internal and external failure.
Can't tell without a Range chart.
Kaoru Ishikawa.

12. Define takt time.
Blame.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
A brainstorming tool that shows the connections between ideas.
The cycle time required to meet demand.

13. List two appraisal costs.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Variable.
Method developed by Ishikawa to graphically display the causes of any given problem

14. A process is operating "in control." Does this mean the customer's requirements are met?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The target number of standard deviations from the mean for specifications.
Linearity - normality - homoscedasticity - independence.
No -- only if the process is also capable.

15. List two components of prevention cost.
Prevention and appraisal costs are balanced against internal and external failure.
QFD
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

16. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
=sqrt((p*(1-p)/n)
The secondary characteristics of a product; "bells and whistles."
95%
100%

17. In a regression - what does the standard error of the estimate tell you?
Actual drawings - layouts - maps - etc which show where a defect occurs
Shows the temporal flow of activities in a project network.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
To do a capability study for a non-centered process.

18. What do you do when a process is out of control?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Look for the assignable cause of non-random variation.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Scrap - rework - retest - downtime - yield losses - disposition costs.

19. When yields decrease - what are the two effects on contribution?
Fewer good units to sell - increased variable cost/unit.
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.
Before production starts
Variable.

20. FMEA
A tool that shows performance along key dimensions all at once.
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
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
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

21. Detection Criteria Ranking
Fishbone - cause-and-effect diagram.
10 if Almost impossible to detect
A tool that shows where there is waste in a process.
The degree to which a product meets pre-established standards.

22. In the Service Quality Gap Model - what is Gap 3?
The gap between specifications and how service is performed.
95%
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
Organize ideas into meaningful categories by recognizing their underlying similarity

23. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Is what induces the failure
Variable.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
p-bar - the long-run percent defective.

24. What size should samples be for attribute SPC?
Large enough to find two of the attribute - on average.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
A descending order-sorted bar chart with a cumulative percentage line.
Lower skill requirements - faster - less chance for error.

25. Pareto Analysis
Deming.
Stratify a particular defect type according to logical criteria
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Brand image.

26. What does Crosby say about benchmarking?
The degree to which a product meets pre-established standards.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Lower skill requirements - faster - less chance for error.
X-bar-bar

27. What is the difference between the way sampling is done for SPC and for acceptance sampling?
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
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
The gap between what customers expect and the service they receive.
Sampling for SPC is done real time.

28. What is a network diagram?
A tool that shows where there is waste in a process.
A diagram that shows the relationships between activities in a project network.
Variable.
Assigns scores to weighted criteria for each project under consideration.

29. What is the center line of an X-bar chart?
Fewer good units to sell - increased variable cost/unit.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
X-bar-bar
Blame.

30. Defect location check sheets
To mentor/coach (and sometimes train) black belts.
The primary operating characteristics of a product.
Actual drawings - layouts - maps - etc which show where a defect occurs
A brainstorming tool that shows the connections between ideas.

31. Test for Independence
The primary operating characteristics of a product.
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
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Not necessarily.

32. What is poka yoke?
Causes that lead to a particular effect.
A tool that shows the physical flows through a space.
They move closer to the center line.
Mistake-proofing.

33. What is the formula for standard deviation?
Hold all input variables constant except one. Observe the response as you vary the single input.
=sqrt(Σ(x-x-bar)^2)/(n-1))
p-bar - the long-run percent defective.
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).

34. Failure effect
Is the consequence of the failure.
To mentor/coach (and sometimes train) black belts.
Initiated before or at design concept finalization
The target number of standard deviations from the mean for specifications.

35. Uses of regression
Method developed by Ishikawa to graphically display the causes of any given problem
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Critical to quality.
Observed variation in response is caused by the input

36. What are the 5 Ss?
Through producer/consumer negotiation.
Causes that lead to a particular effect.
Sort - Set in Order - Shine - Standardize - Sustain
Speed - courtesy - competence - and ease of repair.

37. What is DMADV?
Organize ideas into meaningful categories by recognizing their underlying similarity
A tool that shows performance along key dimensions all at once.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Define - measure - analyze - design - verify.

38. Risk Priority Number RPN
Failure Modes and Effects Analysis
Speed - courtesy - competence - and ease of repair.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

39. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
Mean time to replacement.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
A descending order-sorted bar chart with a cumulative percentage line.

40. What is the center line of a p-chart?
To obtain a certain desirable outcome from the process
They move closer to the center line.
p-bar - the long-run percent defective.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

41. What is Little's Law?
Is what induces the failure
3.4 (assuming 1.5 sigma shift in the mean)
Inventory = throughput x flow time.
50%

42. Cause and Effect Diagrams
A diagram that shows the relationships between activities in a project network.
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
Method developed by Ishikawa to graphically display the causes of any given problem
Variable.

43. FMEA
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
It looks to minimize the probability of a failure - or to minimize its effects
Mistake-proofing.
An assertion or conjecture concerning one or more populations

44. Failure Mode
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).
To manage the Six Sigma project.
Is the way in which the failure is manifested.
The primary operating characteristics of a product.

45. What is Jidoka?
Controlling quality at the source.
Producer risk.
Mean time to replacement.
Lean (or JIT).

46. Histogram by Hand
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
Variable.
A tool that shows performance along key dimensions all at once.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

47. F value
Attribute
Walter A. Shewhart
A descending order-sorted bar chart with a cumulative percentage line.
F_alpha - df(tr) - df (error)

48. What is CTQ?
Financial - customer - internal process - innovation and learning.
Critical to quality.
A tool that shows the physical flows through a space.
No -- the variation also has to be random and "expected."

49. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
= 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
Fewer good units to sell - increased variable cost/unit.
Lower skill requirements - faster - less chance for error.
The gap between what customers expect and the service they receive.

50. With Six Sigma capability - how many defects per million opportunities would you see?
3.4 (assuming 1.5 sigma shift in the mean)
Taguchi
To obtain a certain desirable outcome from the process
68%