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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. Pareto Analysis
Pleasing to the senses.
Producer risk.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Waste.

2. Design of Experiments (DOE) approach
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
5%
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
68%

3. How does Juran define quality?
Actual drawings - layouts - maps - etc which show where a defect occurs
Fitness for use.
A brainstorming tool that shows the connections between ideas.
Variable.

4. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
68%
Rapid improvement process.
Supplier - input - process - output - customer.
Technical quality is the "what" of the service; functional quality is the "how."

5. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
The House of Quality.
95%
Fitness for use.

6. What does a project prioritization matrix do?
The target number of standard deviations from the mean for specifications.
Fewer good units to sell - increased variable cost/unit.
Fitness for use.
Assigns scores to weighted criteria for each project under consideration.

7. What is the center line of an X-bar chart?
The US national quality award.
X-bar-bar
Failure Modes and Effects Analysis
If the Response vs. Levels graph if the response lines are not parallel (crossing)

8. Risk Priority Number RPN
Method developed by Ishikawa to graphically display the causes of any given problem
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Controlling quality at the source.
Shows the temporal flow of activities in a project network.

9. In the Service Quality Gap Model - what is Gap 5?
The gap between what customers expect and the service they receive.
Fitness for use.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Lean (or JIT).

10. 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).
The gap between what management thinks customers want and what customers really want.
Fewer good units to sell - increased variable cost/unit.
A brainstorming tool that shows the connections between ideas.

11. Complete this quality phrase: 'Fix the process - not the _____.'
Blame.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Can't tell without a Range chart.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

12. Does it ever make sense to accept a job when a process is incapable?
The degree to which a product meets pre-established standards.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
A brainstorming tool that shows the connections between ideas.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

13. What is a histogram?
A tool that shows the physical flows through a space.
Mean time to failure.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Define - measure - analyze - design - verify.

14. What is poka yoke?
Technical quality is the "what" of the service; functional quality is the "how."
Mistake-proofing.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
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

15. Test for Independence
No -- if it is not the same - it can only be worse!
Concluding there has not been an effect/change when there has.
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
Someone who is consistently against virtually everything.

16. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
X-bar-bar
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
99.73%

17. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Rapid improvement process.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Variable.
No -- the variation also has to be random and "expected."

18. What are the three main categories of assignable cause?
Workers - machines - materials.
Fewer good units to sell - increased variable cost/unit.
Lean is waste reduction - Six Sigma is variation reduction.
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

19. In a Z table - what is Z?
Fewer good units to sell - increased variable cost/unit.
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))
The number of standard deviations some value is from the mean.

20. Defect location check sheets
The ability of a process to consistently meet customer specifications.
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
Initiated before or at design concept finalization
Actual drawings - layouts - maps - etc which show where a defect occurs

21. Affinity Diagrams
10 for Hazardous without warning 1 for none
Observed variation in response is caused by the input
Because the mean and standard deviation are independent of each other.
Organize ideas into meaningful categories by recognizing their underlying similarity

22. One factor at a time (OFAT)
Kaoru Ishikawa.
Hold all input variables constant except one. Observe the response as you vary the single input.
The gap between what management thinks customers want and the process specifications.
An assertion or conjecture concerning one or more populations

23. Define performance quality.
Through producer/consumer negotiation.
3.4 (assuming 1.5 sigma shift in the mean)
The primary operating characteristics of a product.
Can't tell without a Range chart.

24. Creating a Run Chart
To do a capability study for a non-centered process.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
68%
Lean is waste reduction - Six Sigma is variation reduction.

25. In Juran's Cost of Quality model - which categories of costs balance which other categories?
50%
Supplier - input - process - output - customer.
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).
Prevention and appraisal costs are balanced against internal and external failure.

26. Test for constant variance
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.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Inventory = throughput x flow time.
Shifts - Trends - Repeating patterns - Correlation with known events

27. Define perceived quality (Garvin's framework).
Fewer good units to sell - increased variable cost/unit.
Brand image.
No -- the variation also has to be random and "expected."
QFD

28. If you can only collect categorical data - what type of SPC charting can you do?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Attribute.
Organize ideas into meaningful categories by recognizing their underlying similarity
Fractional factorial designs (orthogonal arrays)

29. What is Kaizen?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Because the mean and standard deviation are independent of each other.
Rapid improvement process.
Fractional factorial designs (orthogonal arrays)

30. What does Crosby say about benchmarking?
Kaoru Ishikawa.
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
Brand image.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

31. What are the 5 Ss?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Sort - Set in Order - Shine - Standardize - Sustain
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Hold all input variables constant except one. Observe the response as you vary the single input.

32. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Upper control limit.
Conformance to specifications.

33. What is the difference between Lean and Six Sigma?
Lean is waste reduction - Six Sigma is variation reduction.
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
Stratify a particular defect type according to logical criteria
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

34. Define features.
Initiated before or at design concept finalization
The secondary characteristics of a product; "bells and whistles."
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:
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

35. FMEA
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
It looks to minimize the probability of a failure - or to minimize its effects
Defects Per Million Opportunities
=sqrt((p*(1-p)/n)

36. Who is a process owner?
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
3.4 (assuming 1.5 sigma shift in the mean)
Deming.
The manager in charge of a process being improved in a Six Sigma project.

37. In the Service Quality Gap Model - what is Gap 3?
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Workers - machines - materials.
The gap between specifications and how service is performed.
Walter A. Shewhart

38. What is Jidoka?
QFD
Producer risk.
Used to create frequency distribution tally sheets
Controlling quality at the source.

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. Who developed the fishbone diagram?
A tool that shows where there is waste in a process.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Kaoru Ishikawa.
Mistake-proofing.

41. What are the four categories of costs in Juran's framework?
A brainstorming tool that shows the connections between ideas.
Prevention - appraisal - internal failure - external failure.
No -- the variation also has to be random and "expected."
Reliability - Assurance - Responsiveness - Tangibles - Empathy

42. What does the abbreviation UCL stand for?
Upper control limit.
Shifts - Trends - Repeating patterns - Correlation with known events
The number of standard deviations some value is from the mean.
Different types of defects are listed (used for Pareto chart)

43. Failure Mode
Is the way in which the failure is manifested.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

44. A process is operating "in control." Does this mean the customer's requirements are met?
No -- only if the process is also capable.
3.4 (assuming 1.5 sigma shift in the mean)
Fewer good units to sell - increased variable cost/unit.
95%

45. What do you do when a process is out of control?
Assigns scores to weighted criteria for each project under consideration.
Look for the assignable cause of non-random variation.
Pleasing to the senses.
The cycle time required to meet demand.

46. What are the four regression assumptions?
Organize ideas into meaningful categories by recognizing their underlying similarity
Linearity - normality - homoscedasticity - independence.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Variable.

47. What does the abbreviation LCL stand for?
Lower control limit.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Actual drawings - layouts - maps - etc which show where a defect occurs
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

48. In a regression - what does the standard error of the estimate tell you?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
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
Organize ideas into meaningful categories by recognizing their underlying similarity
Stratify a particular defect type according to logical criteria

49. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Attribute.
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).
No -- the variation also has to be random and "expected."
Linearity - normality - homoscedasticity - independence.

50. Definition of Interaction
Represents the behavior of a process
Define - measure - analyze - design - verify.
Lean (or JIT).
An interaction is defined as a dependence relationship between the response and the levels of two or more variables