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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. Which type of SPC measurement is more precise - variable or attribute?
To monitor a process when measurement by variables is used.
A time series plot.
Large enough to find two of the attribute - on average.
Variable.

2. Your production process meets customer specifications. Is your process in control?
A brainstorming tool that shows the connections between ideas.
The US national quality award.
Not necessarily.
Lean (or JIT).

3. Failure Mode
Rapid improvement process.
Is the way in which the failure is manifested.
Fractional factorial designs (orthogonal arrays)
Mean time to replacement.

4. Creating a Run Chart
Central Limit Theorem
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Method developed by Ishikawa to graphically display the causes of any given problem
A diagram that shows the relationships between activities in a project network.

5. DOE
Kaoru Ishikawa.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Fishbone - cause-and-effect diagram.
Mean time to failure.

6. In a regression - what does the coefficient of the intercept tell you
The gap between what is promised and what is delivered.
What the value of the dependent variable is when the independent variable is zero.
Shifts - Trends - Repeating patterns - Correlation with known events
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

7. What happens to control limits on an SPC chart when sample size is increased?
Critical to quality.
They move closer to the center line.
Supplier - input - process - output - customer.
An assertion or conjecture concerning one or more populations

8. What is DMADV?
The House of Quality.
99.73%
Define - measure - analyze - design - verify.
A brainstorming tool that shows the connections between ideas.

9. What are the four categories of costs in Juran's framework?
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Prevention - appraisal - internal failure - external failure.

10. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Pleasing to the senses.
The Japanese national quality award.

11. Uses of regression
The ability of a process to consistently meet customer specifications.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
10 if Almost impossible to detect

12. For what is an x-bar chart used?
Prevention and appraisal costs are balanced against internal and external failure.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
To monitor a process when measurement by variables is used.
No -- the variation also has to be random and "expected."

13. What are the four regression assumptions?
Define - measure - analyze - improve - control.
99.73%
Upper control limit.
Linearity - normality - homoscedasticity - independence.

14. What is a Gantt chart?
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
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.
Shows the temporal flow of activities in a project network.

15. What is the formula for standard deviation?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Organize ideas into meaningful categories by recognizing their underlying similarity
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
=sqrt(Σ(x-x-bar)^2)/(n-1))

16. What is process capability?
Method developed by Ishikawa to graphically display the causes of any given problem
The ability of a process to consistently meet customer specifications.
To manage the Six Sigma project.
F_alpha - df(tr) - df (error)

17. Residual(eij)
= yij - y(bar)i --> value minus sum of that treatment (of row)
To do a capability study for a non-centered process.
The gap between what is promised and what is delivered.
An assertion or conjecture concerning one or more populations

18. What is a dashboard?
Rapid improvement process.
A tool that shows performance along key dimensions all at once.
Defects Per Million Opportunities
Consumer risk.

19. In Juran's Cost of Quality model - which categories of costs balance which other categories?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Through producer/consumer negotiation.
Prevention and appraisal costs are balanced against internal and external failure.
The target number of standard deviations from the mean for specifications.

20. Non-random patterns (Run Charts)
Shifts - Trends - Repeating patterns - Correlation with known events
Variable.
0.9^3 or 72.9%
Not necessarily.

21. What is DPMO?
They move closer to the center line.
False - because each machine will have different natural tolerances.
Defects Per Million Opportunities
Is the way in which the failure is manifested.

22. What is poka yoke?
Define - measure - analyze - design - verify.
A brainstorming tool that shows the connections between ideas.
Mistake-proofing.
F_alpha - df(tr) - df (error)

23. What is muda
X-bar-bar
Initiated before or at design concept finalization
False - because each machine will have different natural tolerances.
Waste.

24. Definition of Interaction
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
A descending order-sorted bar chart with a cumulative percentage line.
68%
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

25. In a regression - what does R-square tell you?
Observed variation in response is caused by the input
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
A scatterplot.
95%

26. What are two other names for an Ishikawa diagram?
Lean is waste reduction - Six Sigma is variation reduction.
Prevention - appraisal - internal failure - external failure.
Fishbone - cause-and-effect diagram.
Technical quality is the "what" of the service; functional quality is the "how."

27. List two appraisal costs.
The House of Quality.
To obtain a certain desirable outcome from the process
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The gap between what management thinks customers want and what customers really want.

28. How does Juran define quality?
Before production starts
The gap between specifications and how service is performed.
Fitness for use.
Sampling for SPC is done real time.

29. Affinity Diagrams
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Organize ideas into meaningful categories by recognizing their underlying similarity
Studying firms with the best performance in a particular area.

30. What are the Five Dimensions of Service Quality?
Brand image.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Prevention and appraisal costs are balanced against internal and external failure.
5%

31. Histogram by Hand
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).
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
Can't tell without a Range chart.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

32. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
Shifts - Trends - Repeating patterns - Correlation with known events
95%
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
p-bar - the long-run percent defective.

33. 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?
The gap between what management thinks customers want and the process specifications.
False - because each machine will have different natural tolerances.
F_alpha - df(tr) - df (error)
Fishbone - cause-and-effect diagram.

34. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Represents the behavior of a process
The degree to which a product meets pre-established standards.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
68%

35. TWO-DIMENTIONAL SCATTER PLOT
Financial - customer - internal process - innovation and learning.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
50%
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

36. What is a CAVE man?
Someone who is consistently against virtually everything.
Concluding there has not been an effect/change when there has.
QFD
To monitor a process when measurement by variables is used.

37. Who developed the fishbone diagram?
Kaoru Ishikawa.
100%
Is the way in which the failure is manifested.
F_alpha - df(tr) - df (error)

38. What is the formula for the standard deviation of a proportion?
The cycle time required to meet demand.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Shows the temporal flow of activities in a project network.
=sqrt((p*(1-p)/n)

39. When is Cpk used?
99.73%
Prevention - appraisal - internal failure - external failure.
No -- the variation also has to be random and "expected."
To do a capability study for a non-centered process.

40. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Variable.
To obtain a certain desirable outcome from the process
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).

41. Define durability.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
The number of standard deviations some value is from the mean.
Mean time to replacement.
QFD

42. In the Service Quality Gap Model - what is Gap 5?
The gap between what customers expect and the service they receive.
Observed variation in response is caused by the input
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Can't tell without a Range chart.

43. What is a spaghetti diagram?
68%
To mentor/coach (and sometimes train) black belts.
A tool that shows the physical flows through a space.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

44. Defect location check sheets
Actual drawings - layouts - maps - etc which show where a defect occurs
A tool that shows the physical flows through a space.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
The US national quality award.

45. What does the abbreviation UCL stand for?
Upper control limit.
Shifts - Trends - Repeating patterns - Correlation with known events
Sort - Set in Order - Shine - Standardize - Sustain
To monitor a process when measurement by variables is used.

46. Simple Regression Analysis (one factor regression model)
= 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
95%
No -- if it is not the same - it can only be worse!
Studying firms with the best performance in a particular area.

47. What are the 5 Ss?
The gap between what customers expect and the service they receive.
Because the mean and standard deviation are independent of each other.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Sort - Set in Order - Shine - Standardize - Sustain

48. Residual
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
To monitor a process when measurement by attribute is used.
Assigns scores to weighted criteria for each project under consideration.
Shifts - Trends - Repeating patterns - Correlation with known events

49. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Conformance to specifications.
No -- only if the process is also capable.
To mentor/coach (and sometimes train) black belts.
Is the way in which the failure is manifested.

50. What quality tool formally incorporates the voice of the customer?
Hold all input variables constant except one. Observe the response as you vary the single input.
QFD
Prevention and appraisal costs are balanced against internal and external failure.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.