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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 is Value Stream Mapping?
A tool that shows where there is waste in a process.
To do a capability study for a non-centered process.
Mean time to failure.
100%

2. What is a network diagram?
A diagram that shows the relationships between activities in a project network.
10 if Almost impossible to detect
No -- the variation also has to be random and "expected."
Pleasing to the senses.

3. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
Method developed by Ishikawa to graphically display the causes of any given problem
The manager in charge of a process being improved in a Six Sigma project.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

4. What does the abbreviation UCL stand for?
Upper control limit.
100%
The gap between what is promised and what is delivered.
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:

5. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
Look for the assignable cause of non-random variation.
Shows the temporal flow of activities in a project network.
Concluding there has been an effect/change when there has not.

6. Risk Priority Number RPN
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
It's good -- but it's still out of control!
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
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

7. Test for Independence
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
A time series plot.
False - because each machine will have different natural tolerances.
Pleasing to the senses.

8. Stratified defect check sheets
=sqrt(Σ(x-x-bar)^2)/(n-1))
Stratify a particular defect type according to logical criteria
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.

9. What is the role of a master black belt?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
To mentor/coach (and sometimes train) black belts.
A scatterplot.
Attribute

10. What quality guru emphasizes management as a system?
Deming.
To mentor/coach (and sometimes train) black belts.
The gap between what is promised and what is delivered.
The gap between what management thinks customers want and what customers really want.

11. For what is a p-chart used?
To monitor a process when measurement by attribute is used.
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
Causes that lead to a particular effect.
The secondary characteristics of a product; "bells and whistles."

12. One factor at a time (OFAT)
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Taguchi
Observed variation in response is caused by the input
The ability of a process to consistently meet customer specifications.

13. What is the Deming Prize?
The Japanese national quality award.
= 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
To monitor a process when measurement by variables is used.
The ratio of outputs to inputs; 1-scrap.

14. FMEA
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
Blame.
False - because each machine will have different natural tolerances.
Prevention - appraisal - internal failure - external failure.

15. Design of Experiments (DOE) approach
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
QFD
Lower control limit.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

16. One factor at a time (OFAT)
To manage the Six Sigma project.
Variable.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Hold all input variables constant except one. Observe the response as you vary the single input.

17. What are the four perspectives of the Balanced Scorecard?
Blame.
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
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).
Financial - customer - internal process - innovation and learning.

18. What size should samples be for attribute SPC?
Look for the assignable cause of non-random variation.
Walter A. Shewhart
Concluding there has not been an effect/change when there has.
Large enough to find two of the attribute - on average.

19. What do you do when a process is out of control?
To obtain a certain desirable outcome from the process
Scrap - rework - retest - downtime - yield losses - disposition costs.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Look for the assignable cause of non-random variation.

20. Define benchmarking.
Studying firms with the best performance in a particular area.
Assigns scores to weighted criteria for each project under consideration.
The ability of a process to consistently meet customer specifications.
Define - measure - analyze - improve - control.

21. Statistical Hypothesis
Brand image.
An assertion or conjecture concerning one or more populations
The degree to which a product meets pre-established standards.
Lower skill requirements - faster - less chance for error.

22. What is a Pareto chart?
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
A descending order-sorted bar chart with a cumulative percentage line.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Fewer good units to sell - increased variable cost/unit.

23. If a three-stage process has 90% yields at each stage - what is the overall yield?
Mistake-proofing.
0.9^3 or 72.9%
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Pleasing to the senses.

24. What is a Gantt chart?
Linearity - normality - homoscedasticity - independence.
Initiated before or at design concept finalization
Through producer/consumer negotiation.
Shows the temporal flow of activities in a project network.

25. Advantages of DOE
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Prevention and appraisal costs are balanced against internal and external failure.
The gap between what customers expect and the service they receive.
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

26. Histogram by Hand
99.73%
Defects Per Million Opportunities
The primary operating characteristics of a product.
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

27. Who developed the fishbone diagram?
An assertion or conjecture concerning one or more populations
Kaoru Ishikawa.
A random variable that summarizes the information from the sample(s).
95%

28. List Garvin's eight dimensions of product quality.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
0.9^3 or 72.9%

29. List two components of external failure.
10 for Hazardous without warning 1 for none
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Define - measure - analyze - improve - control.
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).

30. If you can only collect categorical data - what type of SPC charting can you do?
Failure Modes and Effects Analysis
Attribute.
Pleasing to the senses.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

31. If you have calculated a Cpk - should you also calculate a Cp?
Linearity - normality - homoscedasticity - independence.
Rapid improvement process.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Is the way in which the failure is manifested.

32. The Test Statistic (TS)
Hold all input variables constant except one. Observe the response as you vary the single input.
A random variable that summarizes the information from the sample(s).
What the value of the dependent variable is when the independent variable is zero.
F_alpha - df(tr) - df (error)

33. In the Service Quality Gap Model - what is Gap 3?
The gap between specifications and how service is performed.
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).
Organize ideas into meaningful categories by recognizing their underlying similarity
A tool that shows where there is waste in a process.

34. What is process capability?
The ability of a process to consistently meet customer specifications.
Different types of defects are listed (used for Pareto chart)
To obtain a certain desirable outcome from the process
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 is a process owner?
Sort - Set in Order - Shine - Standardize - Sustain
The gap between specifications and how service is performed.
The ratio of outputs to inputs; 1-scrap.
The manager in charge of a process being improved in a Six Sigma project.

36. Why do you need two control charts for variables SPC?
Fitness for use.
Fewer good units to sell - increased variable cost/unit.
Supplier - input - process - output - customer.
Because the mean and standard deviation are independent of each other.

37. In a regression - what does the standard error of the estimate tell you?
The gap between what is promised and what is delivered.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
The manager in charge of a process being improved in a Six Sigma project.

38. What is Type 1 Error?
Concluding there has been an effect/change when there has not.
Lower control limit.
Brand image.
The gap between what is promised and what is delivered.

39. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Lower skill requirements - faster - less chance for error.
A random variable that summarizes the information from the sample(s).
Speed - courtesy - competence - and ease of repair.
Variable.

40. Define perceived quality (Garvin's framework).
= yij - y(bar)i --> value minus sum of that treatment (of row)
68%
QFD
Brand image.

41. What does DMAIC stand for?
A diagram that shows the relationships between activities in a project network.
0.9^3 or 72.9%
Assigns scores to weighted criteria for each project under consideration.
Define - measure - analyze - improve - control.

42. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
To monitor a process when measurement by attribute is used.
100%
Is the consequence of the failure.

43. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
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
Through producer/consumer negotiation.
Shifts - Trends - Repeating patterns - Correlation with known events
Lean (or JIT).

44. Regression
Deming.
False - because each machine will have different natural tolerances.
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
Represents the behavior of a process

45. Daniel Test
Prevention - appraisal - internal failure - external failure.
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)
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:

46. What is the center line of an X-bar chart?
p-bar - the long-run percent defective.
The gap between what customers expect and the service they receive.
To obtain a certain desirable outcome from the process
X-bar-bar

47. Define product reliability.
Can't tell without a Range chart.
Variable.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Mean time to failure.

48. What is the formula for standard deviation?
10 for Hazardous without warning 1 for none
The ratio of outputs to inputs; 1-scrap.
Technical quality is the "what" of the service; functional quality is the "how."
=sqrt(Σ(x-x-bar)^2)/(n-1))

49. How does Juran define quality?
Fitness for use.
A random variable that summarizes the information from the sample(s).
Sort - Set in Order - Shine - Standardize - Sustain
Large enough to find two of the attribute - on average.

50. Define takt time.
Pleasing to the senses.
Workers - machines - materials.
95%
The cycle time required to meet demand.