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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. Regression
Studying firms with the best performance in a particular area.
Represents the behavior of a process
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
The House of Quality.

2. In the Service Quality Gap Model - what is Gap 4?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Method developed by Ishikawa to graphically display the causes of any given problem
The gap between what is promised and what is delivered.
Is the consequence of the failure.

3. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
A brainstorming tool that shows the connections between ideas.
No -- the variation also has to be random and "expected."
Can't tell without a Range chart.
68%

4. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Sampling for SPC is done real time.
The gap between what customers expect and the service they receive.
F_alpha - df(tr) - df (error)
Critical to quality.

5. Cause and Effect Diagrams
Is the consequence of the failure.
Method developed by Ishikawa to graphically display the causes of any given problem
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Kaoru Ishikawa.

6. What is the center line of an X-bar chart?
3.4 (assuming 1.5 sigma shift in the mean)
X-bar-bar
No -- the variation also has to be random and "expected."
The manager in charge of a process being improved in a Six Sigma project.

7. Presence of interaction effect
=sqrt(Σ(x-x-bar)^2)/(n-1))
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A tool that shows performance along key dimensions all at once.

8. Who developed the fishbone diagram?
Organize ideas into meaningful categories by recognizing their underlying similarity
False - because each machine will have different natural tolerances.
To monitor a process when measurement by variables is used.
Kaoru Ishikawa.

9. Simple Regression Analysis (one factor regression model)
Consumer risk.
Lower skill requirements - faster - less chance for error.
= 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
The number of standard deviations some value is from the mean.

10. Daniel Test
Define - measure - analyze - design - verify.
A tool that shows the physical flows through a space.
10 for Hazardous without warning 1 for none
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:

11. Uses of regression
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.
Variable.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

12. Which quality guru developed the concept of loss to society?
100%
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Before production starts
Taguchi

13. What does a project prioritization matrix do?
Mean time to replacement.
Failure Modes and Effects Analysis
Rapid improvement process.
Assigns scores to weighted criteria for each project under consideration.

14. F value
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).
F_alpha - df(tr) - df (error)
Failure Modes and Effects Analysis
Rapid improvement process.

15. What is the 5S model?
The ratio of outputs to inputs; 1-scrap.
Lower control limit.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

16. Who first studied randomness in industrial processes
The ability of a process to consistently meet customer specifications.
Walter A. Shewhart
Shifts - Trends - Repeating patterns - Correlation with known events
Method developed by Ishikawa to graphically display the causes of any given problem

17. The Test Statistic (TS)
Conformance to specifications.
A random variable that summarizes the information from the sample(s).
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Someone who is consistently against virtually everything.

18. What do you do when a process is out of control?
Look for the assignable cause of non-random variation.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Define - measure - analyze - improve - control.

19. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
A time series plot.
Conformance to specifications.
=sqrt(Σ(x-x-bar)^2)/(n-1))

20. Non-random patterns (Run Charts)
Shifts - Trends - Repeating patterns - Correlation with known events
Central Limit Theorem
= yij - y(bar)i --> value minus sum of that treatment (of row)
Waste.

21. Definition of Interaction
A descending order-sorted bar chart with a cumulative percentage line.
Variable.
Through producer/consumer negotiation.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

22. What is Type II Error?
To do a capability study for a non-centered process.
To be a member of a Six Sigma project team.
The gap between what management thinks customers want and the process specifications.
Concluding there has not been an effect/change when there has.

23. What is a Gage R&R?
To be a member of a Six Sigma project team.
5%
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).
Define - measure - analyze - improve - control.

24. If you can only collect categorical data - what type of SPC charting can you do?
A time series plot.
Observed variation in response is caused by the input
Fractional factorial designs (orthogonal arrays)
Attribute.

25. How does Juran define quality?
Used to create frequency distribution tally sheets
Fitness for use.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
A brainstorming tool that shows the connections between ideas.

26. 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
Large enough to find two of the attribute - on average.
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 random variable that summarizes the information from the sample(s).

27. Define aesthetic quality.
The secondary characteristics of a product; "bells and whistles."
Pleasing to the senses.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Taguchi

28. What quality tool formally incorporates the voice of the customer?
QFD
X-bar-bar
Producer risk.
To monitor a process when measurement by attribute is used.

29. Does it ever make sense to accept a job when a process is incapable?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
A random variable that summarizes the information from the sample(s).
Actual drawings - layouts - maps - etc which show where a defect occurs
Method developed by Ishikawa to graphically display the causes of any given problem

30. In the Service Quality Gap Model - what is Gap 3?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Hold all input variables constant except one. Observe the response as you vary the single input.
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
The gap between specifications and how service is performed.

31. Test for Independence
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
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 assertion or conjecture concerning one or more populations
Sort - Set in Order - Shine - Standardize - Sustain

32. Manual Test for Nomality
A tool that shows performance along key dimensions all at once.
Stratify a particular defect type according to logical criteria
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 control limit.

33. What does Crosby say about benchmarking?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Controlling quality at the source.
Before production starts
Producer risk.

34. What does SIPOC stand for?
Waste.
Supplier - input - process - output - customer.
Rapid improvement process.
The gap between what customers expect and the service they receive.

35. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
The gap between what is promised and what is delivered.
Lean (or JIT).
5%
Causes that lead to a particular effect.

36. List two components of external failure.
Variable.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

37. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Prevention and appraisal costs are balanced against internal and external failure.
Financial - customer - internal process - innovation and learning.
Shifts - Trends - Repeating patterns - Correlation with known events

38. Creating a Run Chart
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
An assertion or conjecture concerning one or more populations
To obtain a certain desirable outcome from the process
Walter A. Shewhart

39. What are the four categories of costs in Juran's framework?
10 if Almost impossible to detect
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Prevention - appraisal - internal failure - external failure.
Central Limit Theorem

40. Uses of regression - Control
To manage the Six Sigma project.
To obtain a certain desirable outcome from the process
Failure Modes and Effects Analysis
Initiated before or at design concept finalization

41. A process is operating "in control." Does this mean the customer's requirements are met?
Large enough to find two of the attribute - on average.
Assigns scores to weighted criteria for each project under consideration.
No -- only if the process is also capable.
A scatterplot.

42. In the Service Quality Gap Model - what is Gap 1?
100%
A tool that shows where there is waste in a process.
The gap between what management thinks customers want and what customers really want.
95%

43. What are two other names for an Ishikawa 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
Fishbone - cause-and-effect diagram.
Technical quality is the "what" of the service; functional quality is the "how."
Brand image.

44. List Garvin's eight dimensions of product quality.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
No -- if it is not the same - it can only be worse!
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Different types of defects are listed (used for Pareto chart)

45. DFMEA
100%
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
The gap between what is promised and what is delivered.
Initiated before or at design concept finalization

46. ANOVA

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47. Taguchi's experimental designs are of this type.
Look for the assignable cause of non-random variation.
Fractional factorial designs (orthogonal arrays)
Mean time to replacement.
3.4 (assuming 1.5 sigma shift in the mean)

48. What is the role of a black belt?
Not necessarily.
A diagram that shows the relationships between activities in a project network.
A brainstorming tool that shows the connections between ideas.
To manage the Six Sigma project.

49. Process occurance ranking
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:
Not necessarily.
It looks to minimize the probability of a failure - or to minimize its effects
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

50. Defect check sheets
Sort - Set in Order - Shine - Standardize - Sustain
Taguchi
Different types of defects are listed (used for Pareto chart)
Consumer risk.