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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. Residual(eij)
= yij - y(bar)i --> value minus sum of that treatment (of row)
Concluding there has been an effect/change when there has not.
Producer risk.
Someone who is consistently against virtually everything.

2. What is a Gage R&R?
Is the way in which the failure is manifested.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
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).

3. Failure effect
Is the consequence of the failure.
No -- if it is not the same - it can only be worse!
Critical to quality.
Lean is waste reduction - Six Sigma is variation reduction.

4. Which type of SPC measurement is more precise - variable or attribute?
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).
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Speed - courtesy - competence - and ease of repair.
Variable.

5. If a three-stage process has 90% yields at each stage - what is the overall yield?
Causes that lead to a particular effect.
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.
0.9^3 or 72.9%

6. Creating a Run Chart
To do a capability study for a non-centered process.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Fishbone - cause-and-effect diagram.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

7. Detection Criteria Ranking
10 if Almost impossible to detect
The number of standard deviations some value is from the mean.
The secondary characteristics of a product; "bells and whistles."
Speed - courtesy - competence - and ease of repair.

8. FMEA
The Japanese national quality award.
Through producer/consumer negotiation.
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
Consumer risk.

9. Daniel Test
No -- only if the process is also capable.
False - because each machine will have different natural tolerances.
= 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
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:

10. Affinity Diagrams
Walter A. Shewhart
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Central Limit Theorem
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

11. Define perceived quality (Garvin's framework).
Lean (or JIT).
Brand image.
It looks to minimize the probability of a failure - or to minimize its effects
Variable.

12. What is the formula for standard deviation?
Taguchi
=sqrt(Σ(x-x-bar)^2)/(n-1))
To monitor a process when measurement by attribute is used.
It looks to minimize the probability of a failure - or to minimize its effects

13. Define features.
Workers - machines - materials.
An assertion or conjecture concerning one or more populations
The secondary characteristics of a product; "bells and whistles."
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

14. Based on what principal can we use the normal distribution assumptions for SPC?
Rapid improvement process.
They move closer to the center line.
Look for the assignable cause of non-random variation.
Central Limit Theorem

15. Test for constant variance
A tool that shows where there is waste in a process.
Is the consequence of the failure.
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.
A brainstorming tool that shows the connections between ideas.

16. Risk Priority Number RPN
Before production starts
To be a member of a Six Sigma project team.
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

17. Design of Experiments (DOE) approach
Fitness for use.
It looks to minimize the probability of a failure - or to minimize its effects
Because the mean and standard deviation are independent of each other.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

18. What is the center line of an X-bar chart?
X-bar-bar
Observed variation in response is caused by the input
The gap between what management thinks customers want and the process specifications.
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

19. Uses of regression
To monitor a process when measurement by attribute is used.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
False - because each machine will have different natural tolerances.
Organize ideas into meaningful categories by recognizing their underlying similarity

20. What is CTQ?
Critical to quality.
False - because each machine will have different natural tolerances.
Lower control limit.
=sqrt(Σ(x-x-bar)^2)/(n-1))

21. For what is a p-chart used?
Upper control limit.
Pleasing to the senses.
Assigns scores to weighted criteria for each project under consideration.
To monitor a process when measurement by attribute is used.

22. In the Service Quality Gap Model - what is Gap 1?
A random variable that summarizes the information from the sample(s).
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The gap between what management thinks customers want and what customers really want.

23. What is Type II Error?
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Concluding there has not been an effect/change when there has.
68%
Technical quality is the "what" of the service; functional quality is the "how."

24. What is written on the "spines" of a fishbone diagram?
Causes that lead to a particular effect.
10 for Hazardous without warning 1 for none
Concluding there has been an effect/change when there has not.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

25. In the Service Quality Gap Model - what is Gap 2?
0.9^3 or 72.9%
Hold all input variables constant except one. Observe the response as you vary the single input.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The gap between what management thinks customers want and the process specifications.

26. What is the difference between Lean and Six Sigma?
Lean is waste reduction - Six Sigma is variation reduction.
Workers - machines - materials.
0.9^3 or 72.9%
Someone who is consistently against virtually everything.

27. Test for Independence
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
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
Fishbone - cause-and-effect diagram.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

28. What is poka yoke?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Lower skill requirements - faster - less chance for error.
Mistake-proofing.
Lean (or JIT).

29. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
A diagram that shows the relationships between activities in a project network.
Fishbone - cause-and-effect diagram.
The gap between what is promised and what is delivered.

30. What quality tool formally incorporates the voice of the customer?
Financial - customer - internal process - innovation and learning.
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
QFD
What the value of the dependent variable is when the independent variable is zero.

31. What is a Pareto chart?
To mentor/coach (and sometimes train) black belts.
A descending order-sorted bar chart with a cumulative percentage line.
QFD
Define - measure - analyze - design - verify.

32. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
An assertion or conjecture concerning one or more populations
Lean is waste reduction - Six Sigma is variation reduction.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
95%

33. Non-random patterns (Run Charts)
Because the mean and standard deviation are independent of each other.
Walter A. Shewhart
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
Shifts - Trends - Repeating patterns - Correlation with known events

34. Who developed the fishbone diagram?
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
A brainstorming tool that shows the connections between ideas.
Kaoru Ishikawa.
=sqrt((p*(1-p)/n)

35. What happens to control limits on an SPC chart when sample size is increased?
It's good -- but it's still out of control!
They move closer to the center line.
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:
Initiated before or at design concept finalization

36. What does the abbreviation LCL stand for?
Linearity - normality - homoscedasticity - independence.
Lower control limit.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Pleasing to the senses.

37. What is FMEA?
Critical to quality.
Failure Modes and Effects Analysis
Hold all input variables constant except one. Observe the response as you vary the single input.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

38. 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.
Conformance to specifications.
False - because each machine will have different natural tolerances.
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

39. List two components of internal failure.
Large enough to find two of the attribute - on average.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Blame.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

40. What is DMADV?
Lean (or JIT).
Define - measure - analyze - design - verify.
Not necessarily.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

41. What is the Deming Prize?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
The Japanese national quality award.
They move closer to the center line.
Central Limit Theorem

42. 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.
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
Fewer good units to sell - increased variable cost/unit.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

43. Pareto Analysis
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Rapid improvement process.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
To monitor a process when measurement by attribute is used.

44. FMEA
Organize ideas into meaningful categories by recognizing their underlying similarity
Brand image.
It looks to minimize the probability of a failure - or to minimize its effects
Represents the behavior of a process

45. DFMEA
Is the consequence of the failure.
Attribute.
QFD
Initiated before or at design concept finalization

46. What type of risk is associated with Type II Error?
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Define - measure - analyze - design - verify.
Consumer risk.
Is the consequence of the failure.

47. What type of risk is associated with Type 1 Error?
Producer risk.
The gap between what customers expect and the service they receive.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
A diagram that shows the relationships between activities in a project network.

48. Who is a process owner?
Studying firms with the best performance in a particular area.
A time series plot.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The manager in charge of a process being improved in a Six Sigma project.

49. When yields decrease - what are the two effects on contribution?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Fewer good units to sell - increased variable cost/unit.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
The gap between what is promised and what is delivered.

50. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
Is the way in which the failure is manifested.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Is what induces the failure