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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 your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
It's good -- but it's still out of control!
100%
Fractional factorial designs (orthogonal arrays)
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

2. What is Type 1 Error?
Concluding there has been an effect/change when there has not.
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
95%
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

3. List two components of internal failure.
Fewer good units to sell - increased variable cost/unit.
Before production starts
Scrap - rework - retest - downtime - yield losses - disposition costs.
The US national quality award.

4. What is a histogram?
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
Kaoru Ishikawa.
Actual drawings - layouts - maps - etc which show where a defect occurs
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

5. What is DPMO?
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
Defects Per Million Opportunities
Failure Modes and Effects Analysis
Mean time to failure.

6. What percentage of a normal distribution lies above the mean?
The degree to which a product meets pre-established standards.
Kaoru Ishikawa.
Producer risk.
50%

7. Define perceived quality (Garvin's framework).
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
Assigns scores to weighted criteria for each project under consideration.
Taguchi
Brand image.

8. What is the formula for standard deviation?
=sqrt(Σ(x-x-bar)^2)/(n-1))
A tool that shows the physical flows through a space.
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
5%

9. In the Service Quality Gap Model - what is Gap 3?
Lower skill requirements - faster - less chance for error.
An assertion or conjecture concerning one or more populations
Defects Per Million Opportunities
The gap between specifications and how service is performed.

10. Defect check sheets
It looks to minimize the probability of a failure - or to minimize its effects
Different types of defects are listed (used for Pareto chart)
Taguchi
=sqrt((p*(1-p)/n)

11. 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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12. List two components of prevention cost.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
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
To be a member of a Six Sigma project team.
Define - measure - analyze - improve - control.

13. What are the four perspectives of the Balanced Scorecard?
Attribute
Fractional factorial designs (orthogonal arrays)
To monitor a process when measurement by attribute is used.
Financial - customer - internal process - innovation and learning.

14. What is the Baldrige Award?
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
Taguchi
The US national quality award.

15. Uses of regression
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
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).
Is the consequence of the failure.
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).

16. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Speed - courtesy - competence - and ease of repair.
Conformance to specifications.
95%
Reliability - Assurance - Responsiveness - Tangibles - Empathy

17. Define takt time.
The cycle time required to meet demand.
Variable.
Can't tell without a Range chart.
Controlling quality at the source.

18. What type of risk is associated with Type 1 Error?
Producer risk.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
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
Concluding there has been an effect/change when there has not.

19. Does it ever make sense to accept a job when a process is incapable?
Before production starts
To monitor a process when measurement by attribute is used.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Deming.

20. What graphical tool is used to show the relationship between two numerical variables?
A scatterplot.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
0.9^3 or 72.9%
Lower skill requirements - faster - less chance for error.

21. What does DMAIC stand for?
Define - measure - analyze - improve - control.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

22. In a regression - what does R-square tell you?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Is the consequence of the failure.
Actual drawings - layouts - maps - etc which show where a defect occurs

23. Disadvantages of DOE

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24. Explain the difference between technical and functional service quality.
Technical quality is the "what" of the service; functional quality is the "how."
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:
Through producer/consumer negotiation.
A tool that shows the physical flows through a space.

25. In the Service Quality Gap Model - what is Gap 4?
Speed - courtesy - competence - and ease of repair.
To obtain a certain desirable outcome from the process
The gap between what is promised and what is delivered.
Someone who is consistently against virtually everything.

26. What do you do when a process is out of control?
Defects Per Million Opportunities
Reliability - Assurance - Responsiveness - Tangibles - Empathy
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
Look for the assignable cause of non-random variation.

27. For what is an x-bar chart used?
To monitor a process when measurement by variables is used.
Lean (or JIT).
Fitness for use.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

28. What is a Gantt chart?
To obtain a certain desirable outcome from the process
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Shows the temporal flow of activities in a project network.
Prevention - appraisal - internal failure - external failure.

29. Defect location check sheets
Actual drawings - layouts - maps - etc which show where a defect occurs
Attribute.
Organize ideas into meaningful categories by recognizing their underlying similarity
Shifts - Trends - Repeating patterns - Correlation with known events

30. In the Service Quality Gap Model - what is Gap 1?
The US national quality award.
The gap between what management thinks customers want and what customers really want.
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
Financial - customer - internal process - innovation and learning.

31. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
68%
=sqrt((p*(1-p)/n)
The House of Quality.
Sampling for SPC is done real time.

32. When either attribute or variable measures could be used for SPC - why might attribute measurement be preferred?
Lean (or JIT).
Lower skill requirements - faster - less chance for error.
Assigns scores to weighted criteria for each project under consideration.
Define - measure - analyze - design - verify.

33. One factor at a time (OFAT)
Mistake-proofing.
Define - measure - analyze - design - verify.
Observed variation in response is caused by the input
Fitness for use.

34. What is DMADV?
Define - measure - analyze - design - verify.
X-bar-bar
A tool that shows performance along key dimensions all at once.
Defects Per Million Opportunities

35. What quality tool formally incorporates the voice of the customer?
QFD
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Variable.

36. Manual Test for Nomality
10 if Almost impossible to detect
Speed - courtesy - competence - and ease of repair.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Lower skill requirements - faster - less chance for error.

37. Creating a Run Chart
The target number of standard deviations from the mean for specifications.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Prevention - appraisal - internal failure - external failure.
Attribute

38. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Before production starts
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Outside.
Observed variation in response is caused by the input

39. What is Value Stream Mapping?
A tool that shows where there is waste in a process.
Different types of defects are listed (used for Pareto chart)
10 for Hazardous without warning 1 for none
68%

40. Your production process meets customer specifications. Is your process in control?
Not necessarily.
The gap between specifications and how service is performed.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
A random variable that summarizes the information from the sample(s).

41. What is the center line of an X-bar chart?
X-bar-bar
Through producer/consumer negotiation.
Consumer risk.
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

42. Non-random patterns (Run Charts)
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Someone who is consistently against virtually everything.
Shifts - Trends - Repeating patterns - Correlation with known events

43. What is the Deming Prize?
Shifts - Trends - Repeating patterns - Correlation with known events
To monitor a process when measurement by attribute is used.
The Japanese national quality award.
Waste.

44. Define performance quality.
The primary operating characteristics of a product.
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
50%
The US national quality award.

45. If you have calculated a Cpk - should you also calculate a Cp?
Fractional factorial designs (orthogonal arrays)
Deming.
p-bar - the long-run percent defective.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

46. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
50%
Conformance to specifications.
Define - measure - analyze - design - verify.
Lean is waste reduction - Six Sigma is variation reduction.

47. What is the 5S model?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Supplier - input - process - output - customer.
QFD
Initiated before or at design concept finalization

48. Affinity Diagrams
The US national quality award.
Organize ideas into meaningful categories by recognizing their underlying similarity
Supplier - input - process - output - customer.
Define - measure - analyze - design - verify.

49. Test for Independence
Outside.
No -- only if the process is also capable.
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
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

50. What is a Gage R&R?
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).
Brand image.
10 for Hazardous without warning 1 for none
Defects Per Million Opportunities