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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. What does DMAIC stand for?
No -- if it is not the same - it can only be worse!
Define - measure - analyze - improve - control.
10 for Hazardous without warning 1 for none
=sqrt(Σ(x-x-bar)^2)/(n-1))

2. What quality tool formally incorporates the voice of the customer?
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
Critical to quality.
QFD
To monitor a process when measurement by variables is used.

3. If you have calculated a Cpk - should you also calculate a Cp?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Inventory = throughput x flow time.
Lower control limit.

4. What is FMEA?
A tool that shows the physical flows through a space.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Failure Modes and Effects Analysis
To manage the Six Sigma project.

5. Risk Priority Number RPN
Rapid improvement process.
To mentor/coach (and sometimes train) black belts.
False - because each machine will have different natural tolerances.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

6. Define takt time.
The cycle time required to meet demand.
Critical to quality.
Assigns scores to weighted criteria for each project under consideration.
To do a capability study for a non-centered process.

7. Define durability.
Critical to quality.
Look for the assignable cause of non-random variation.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Mean time to replacement.

8. How are LQL and AQL determined in an acceptance sampling plan?
Lower skill requirements - faster - less chance for error.
Through producer/consumer negotiation.
Someone who is consistently against virtually everything.
A descending order-sorted bar chart with a cumulative percentage line.

9. What is Little's Law?
Inventory = throughput x flow time.
The gap between specifications and how service is performed.
Critical to quality.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

10. In the Service Quality Gap Model - what is Gap 3?
Failure Modes and Effects Analysis
The gap between specifications and how service is performed.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

11. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
Represents the behavior of a process
5%
No -- only if the process is also capable.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

12. What is DMADV?
Mean time to failure.
Define - measure - analyze - design - verify.
To do a capability study for a non-centered process.
Lean is waste reduction - Six Sigma is variation reduction.

13. In a regression - what does the standard error of the estimate tell you?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
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
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.
Used to create frequency distribution tally sheets

14. Affinity Diagrams
Scrap - rework - retest - downtime - yield losses - disposition costs.
Actual drawings - layouts - maps - etc which show where a defect occurs
Technical quality is the "what" of the service; functional quality is the "how."
Organize ideas into meaningful categories by recognizing their underlying similarity

15. What is the role of a black belt?
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).
Lean (or JIT).
Can't tell without a Range chart.
To manage the Six Sigma project.

16. 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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17. For what is an x-bar chart used?
To monitor a process when measurement by variables is used.
The degree to which a product meets pre-established standards.
Upper control limit.
50%

18. Residual
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Hold all input variables constant except one. Observe the response as you vary the single input.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
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:

19. Regression
Brand image.
Represents the behavior of a process
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
A scatterplot.

20. What happens to control limits on an SPC chart when sample size is increased?
Initiated before or at design concept finalization
99.73%
The secondary characteristics of a product; "bells and whistles."
They move closer to the center line.

21. What is an affinity diagram?
50%
Because the mean and standard deviation are independent of each other.
A brainstorming tool that shows the connections between ideas.
A tool that shows performance along key dimensions all at once.

22. In the Service Quality Gap Model - what is Gap 5?
A time series plot.
Pleasing to the senses.
The gap between what customers expect and the service they receive.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

23. Stratified defect check sheets
10 for Hazardous without warning 1 for none
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).
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Stratify a particular defect type according to logical criteria

24. Defect check sheets
Is the way in which the failure is manifested.
It's good -- but it's still out of control!
To do a capability study for a non-centered process.
Different types of defects are listed (used for Pareto chart)

25. What is a Gage R&R?
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 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).
Someone who is consistently against virtually everything.
The ability of a process to consistently meet customer specifications.

26. What is Type 1 Error?
Before production starts
They move closer to the center line.
Concluding there has been an effect/change when there has not.
Sort - Set in Order - Shine - Standardize - Sustain

27. What is muda
Waste.
99.73%
To be a member of a Six Sigma project team.
Inventory = throughput x flow time.

28. What percentage of a normal distribution lies above the mean?
50%
Large enough to find two of the attribute - on average.
The US national quality award.
=sqrt((p*(1-p)/n)

29. List two components of external failure.
What the value of the dependent variable is when the independent variable is zero.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Variable.

30. Process check sheets
Represents the behavior of a process
Used to create frequency distribution tally sheets
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
Shifts - Trends - Repeating patterns - Correlation with known events

31. If a Cp shows that a process is not capable - should you calculate Cpk?
Shows the temporal flow of activities in a project network.
The gap between what customers expect and the service they receive.
The gap between what management thinks customers want and what customers really want.
No -- if it is not the same - it can only be worse!

32. In a regression - what does the p value of F tell you?
Producer risk.
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).
Prevention and appraisal costs are balanced against internal and external failure.
What the value of the dependent variable is when the independent variable is zero.

33. Define benchmarking.
A random variable that summarizes the information from the sample(s).
Studying firms with the best performance in a particular area.
Mean time to replacement.
The gap between what customers expect and the service they receive.

34. What does the abbreviation UCL stand for?
To monitor a process when measurement by attribute is used.
Prevention - appraisal - internal failure - external failure.
Upper control limit.
The Japanese national quality award.

35. Which quality guru developed the concept of loss to society?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
=sqrt((p*(1-p)/n)
Taguchi

36. Define product reliability.
The degree to which a product meets pre-established standards.
Is what induces the failure
Mean time to failure.
Attribute

37. Failure effect
A descending order-sorted bar chart with a cumulative percentage line.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Is the consequence of the failure.
Supplier - input - process - output - customer.

38. What are the three main categories of assignable cause?
= yij - y(bar)i --> value minus sum of that treatment (of row)
Pleasing to the senses.
A tool that shows where there is waste in a process.
Workers - machines - materials.

39. Creating a Run Chart
Mean time to replacement.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The primary operating characteristics of a product.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

40. What quality guru emphasizes management as a system?
The gap between what is promised and what is delivered.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Deming.
Brand image.

41. How does Juran define quality?
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 gap between what customers expect and the service they receive.
A descending order-sorted bar chart with a cumulative percentage line.
Fitness for use.

42. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Is the consequence of the failure.
The ability of a process to consistently meet customer specifications.
Prevention - appraisal - internal failure - external failure.
Lean (or JIT).

43. Defect location check sheets
Is the way in which the failure is manifested.
Actual drawings - layouts - maps - etc which show where a defect occurs
Hold all input variables constant except one. Observe the response as you vary the single input.
No -- only if the process is also capable.

44. 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
Prevention - appraisal - internal failure - 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
10 if Almost impossible to detect

45. What does a project prioritization matrix do?
Initiated before or at design concept finalization
The House of Quality.
Variable.
Assigns scores to weighted criteria for each project under consideration.

46. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Scrap - rework - retest - downtime - yield losses - disposition costs.
To monitor a process when measurement by attribute is used.
Observed variation in response is caused by the input
99.73%

47. If you can only collect categorical data - what type of SPC charting can you do?
The Japanese national quality award.
Attribute.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Failure Modes and Effects Analysis

48. A process is operating "in control." Does this mean the customer's requirements are met?
Because the mean and standard deviation are independent of each other.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
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
No -- only if the process is also capable.

49. Why do you need two control charts for variables SPC?
Linearity - normality - homoscedasticity - independence.
Variable.
Because the mean and standard deviation are independent of each other.
Concluding there has been an effect/change when there has not.

50. Define yield.
Controlling quality at the source.
The ratio of outputs to inputs; 1-scrap.
Stratify a particular defect type according to logical criteria
Blame.