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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 the role of a green belt?
To monitor a process when measurement by attribute is used.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Is the way in which the failure is manifested.
To be a member of a Six Sigma project team.

2. Defect location check sheets
Prevention and appraisal costs are balanced against internal and external failure.
=sqrt((p*(1-p)/n)
Inventory = throughput x flow time.
Actual drawings - layouts - maps - etc which show where a defect occurs

3. If you can only collect categorical data - what type of SPC charting can you do?
Inventory = throughput x flow time.
Variable.
To monitor a process when measurement by variables is used.
Attribute.

4. What happens to control limits on an SPC chart when sample size is increased?
Pleasing to the senses.
Concluding there has not been an effect/change when there has.
A tool that shows the physical flows through a space.
They move closer to the center line.

5. Disadvantages of DOE

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6. What does SIPOC stand for?
Supplier - input - process - output - customer.
X-bar-bar
Lower skill requirements - faster - less chance for error.
Fractional factorial designs (orthogonal arrays)

7. What does DMAIC stand for?
A descending order-sorted bar chart with a cumulative percentage line.
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
Hold all input variables constant except one. Observe the response as you vary the single input.
Define - measure - analyze - improve - control.

8. What is DMADV?
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
Define - measure - analyze - design - verify.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
It looks to minimize the probability of a failure - or to minimize its effects

9. What is process capability?
To mentor/coach (and sometimes train) black belts.
The US national quality award.
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
The ability of a process to consistently meet customer specifications.

10. Define aesthetic quality.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Pleasing to the senses.
Speed - courtesy - competence - and ease of repair.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

11. What is CTQ?
Workers - machines - materials.
Is the consequence of the failure.
Critical to quality.
Variable.

12. What is a Gantt chart?
Shows the temporal flow of activities in a project network.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Initiated before or at design concept finalization
A time series plot.

13. In a regression - what does the coefficient of the intercept tell you
What the value of the dependent variable is when the independent variable is zero.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
To do a capability study for a non-centered process.
Workers - machines - materials.

14. Failure Mode
68%
Is the way in which the failure is manifested.
The Japanese national quality award.
Actual drawings - layouts - maps - etc which show where a defect occurs

15. What is muda
Supplier - input - process - output - customer.
Waste.
X-bar-bar
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

16. Test for Independence
Critical to quality.
Deming.
Causes that lead to a particular effect.
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

17. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Sampling for SPC is done real time.
= yij - y(bar)i --> value minus sum of that treatment (of row)
95%
3.4 (assuming 1.5 sigma shift in the mean)

18. List two components of prevention cost.
F_alpha - df(tr) - df (error)
10 if Almost impossible to detect
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

19. Effect ranking (Severity of the Defect)
10 for Hazardous without warning 1 for none
Can't tell without a Range chart.
= 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
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

20. What is a network diagram?
A diagram that shows the relationships between activities in a project network.
They move closer to the center line.
The Japanese national quality award.
Fitness for use.

21. Taguchi's experimental designs are of this type.
Fractional factorial designs (orthogonal arrays)
100%
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

22. There are two milling machines in the shop. Data has been collected on one to compute control limits for both. This is acceptable SPC practice - true or false and why?
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
False - because each machine will have different natural tolerances.
Supplier - input - process - output - customer.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

23. What is the role of a black belt?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Defects Per Million Opportunities
No -- only if the process is also capable.
To manage the Six Sigma project.

24. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
95%
Causes that lead to a particular effect.
Because the mean and standard deviation are independent of each other.
It looks to minimize the probability of a failure - or to minimize its effects

25. When is Cpk used?
Define - measure - analyze - design - verify.
Mean time to replacement.
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
To do a capability study for a non-centered process.

26. With Six Sigma capability - how many defects per million opportunities would you see?
To monitor a process when measurement by variables is used.
Concluding there has been an effect/change when there has not.
3.4 (assuming 1.5 sigma shift in the mean)
The gap between specifications and how service is performed.

27. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
QFD
Variable.
Observed variation in response is caused by the input
The Japanese national quality award.

28. The Test Statistic (TS)
Concluding there has been an effect/change when there has not.
A random variable that summarizes the information from the sample(s).
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.

29. A process is operating "in control." Does this mean the customer's requirements are met?
Mistake-proofing.
= 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
Prevention and appraisal costs are balanced against internal and external failure.
No -- only if the process is also capable.

30. What are the four categories of costs in Juran's framework?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Supplier - input - process - output - customer.
Prevention - appraisal - internal failure - external failure.
Large enough to find two of the attribute - on average.

31. Define yield.
Workers - machines - materials.
The ratio of outputs to inputs; 1-scrap.
Brand image.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

32. For what is a p-chart used?
Initiated before or at design concept finalization
To monitor a process when measurement by attribute is used.
The primary operating characteristics of a product.
Linearity - normality - homoscedasticity - independence.

33. What is a run chart?
A time series plot.
To manage the Six Sigma project.
50%
Someone who is consistently against virtually everything.

34. Affinity Diagrams
Upper control limit.
To do a capability study for a non-centered process.
Outside.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

35. What is a CAVE man?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Someone who is consistently against virtually everything.
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

36. Residual
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Kaoru Ishikawa.
Scrap - rework - retest - downtime - yield losses - disposition costs.
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

37. What is the formula for the standard deviation of a proportion?
Before production starts
A diagram that shows the relationships between activities in a project network.
Blame.
=sqrt((p*(1-p)/n)

38. Advantages of DOE
Financial - customer - internal process - innovation and learning.
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
Used to create frequency distribution tally sheets
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. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
100%
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).
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.

41. If a three-stage process has 90% yields at each stage - what is the overall yield?
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
0.9^3 or 72.9%
The gap between what customers expect and the service they receive.
Actual drawings - layouts - maps - etc which show where a defect occurs

42. What is DPMO?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Defects Per Million Opportunities
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
p-bar - the long-run percent defective.

43. What is Type II Error?
Because the mean and standard deviation are independent of each other.
The secondary characteristics of a product; "bells and whistles."
The gap between what customers expect and the service they receive.
Concluding there has not been an effect/change when there has.

44. What is Kaizen?
Fishbone - cause-and-effect diagram.
Rapid improvement process.
10 if Almost impossible to detect
Sampling for SPC is done real time.

45. What type of risk is associated with Type II Error?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Conformance to specifications.
Linearity - normality - homoscedasticity - independence.
Consumer risk.

46. Pareto Analysis
Sort - Set in Order - Shine - Standardize - Sustain
Critical to quality.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

47. What is a Pareto chart?
Used to create frequency distribution tally sheets
A descending order-sorted bar chart with a cumulative percentage line.
Organize ideas into meaningful categories by recognizing their underlying similarity
Central Limit Theorem

48. What graphical tool is used to show the relationship between two numerical variables?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
QFD
A scatterplot.
Shows the temporal flow of activities in a project network.

49. What are the four regression assumptions?
Pleasing to the senses.
Linearity - normality - homoscedasticity - independence.
Is what induces the failure
Look for the assignable cause of non-random variation.

50. What is the formula for standard deviation?
Causes that lead to a particular effect.
Actual drawings - layouts - maps - etc which show where a defect occurs
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
=sqrt(Σ(x-x-bar)^2)/(n-1))