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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. Explain the difference between technical and functional service quality.
Lean (or JIT).
Technical quality is the "what" of the service; functional quality is the "how."
68%
0.9^3 or 72.9%

2. With Six Sigma capability - how many defects per million opportunities would you see?
Producer risk.
Rapid improvement process.
Organize ideas into meaningful categories by recognizing their underlying similarity
3.4 (assuming 1.5 sigma shift in the mean)

3. A process is operating "in control." Does this mean the customer's requirements are met?
A time series plot.
The gap between what management thinks customers want and what customers really want.
The House of Quality.
No -- only if the process is also capable.

4. What are the three main categories of assignable cause?
They move closer to the center line.
Producer risk.
Concluding there has been an effect/change when there has not.
Workers - machines - materials.

5. In the Service Quality Gap Model - what is Gap 5?
Rapid improvement process.
0.9^3 or 72.9%
The gap between what customers expect and the service they receive.
Failure Modes and Effects Analysis

6. How does Juran define quality?
Fitness for use.
To monitor a process when measurement by variables is used.
Rapid improvement process.
Waste.

7. What type of risk is associated with Type 1 Error?
Producer risk.
Kaoru Ishikawa.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Used to create frequency distribution tally sheets

8. When yields decrease - what are the two effects on contribution?
Through producer/consumer negotiation.
False - because each machine will have different natural tolerances.
Waste.
Fewer good units to sell - increased variable cost/unit.

9. Risk Priority Number RPN
The US national quality award.
To do a capability study for a non-centered process.
Brand image.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

10. What is a network diagram?
Fitness for use.
To obtain a certain desirable outcome from the process
The gap between what management thinks customers want and what customers really want.
A diagram that shows the relationships between activities in a project network.

11. What is the difference between the way sampling is done for SPC and for acceptance sampling?
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
The Japanese national quality award.
Sampling for SPC is done real time.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

12. Simple Regression Analysis (one factor regression model)
Sort - Set in Order - Shine - Standardize - Sustain
3.4 (assuming 1.5 sigma shift in the mean)
= 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
Waste.

13. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

14. What are the four regression assumptions?
Mistake-proofing.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Linearity - normality - homoscedasticity - independence.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.

15. Define aesthetic quality.
Pleasing to the senses.
No -- if it is not the same - it can only be worse!
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
=sqrt(Σ(x-x-bar)^2)/(n-1))

16. What is the role of a black belt?
The US national quality award.
To manage the Six Sigma project.
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.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

17. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
The primary operating characteristics of a product.
A tool that shows the physical flows through a space.
Outside.
Lean (or JIT).

18. Effect ranking (Severity of the Defect)
X-bar-bar
Different types of defects are listed (used for Pareto chart)
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
10 for Hazardous without warning 1 for none

19. Disadvantages of DOE

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20. Non-random patterns (Run Charts)
To manage the Six Sigma project.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Shifts - Trends - Repeating patterns - Correlation with known events
Actual drawings - layouts - maps - etc which show where a defect occurs

21. Creating a Run Chart
Attribute.
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
It's good -- but it's still out of control!

22. Stratified defect check sheets
A tool that shows performance along key dimensions all at once.
Stratify a particular defect type according to logical criteria
The ability of a process to consistently meet customer specifications.
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.

23. List Garvin's eight dimensions of product quality.
The gap between what customers expect and the service they receive.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
A time series plot.

24. Defect check sheets
Shifts - Trends - Repeating patterns - Correlation with known events
Different types of defects are listed (used for Pareto chart)
The primary operating characteristics of a product.
100%

25. Define yield.
The target number of standard deviations from the mean for specifications.
Shifts - Trends - Repeating patterns - Correlation with known events
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The ratio of outputs to inputs; 1-scrap.

26. Histogram by Hand
The target number of standard deviations from the mean for specifications.
Supplier - input - process - output - customer.
Mistake-proofing.
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

27. What is the role of a master black belt?
Through producer/consumer negotiation.
To mentor/coach (and sometimes train) black belts.
An assertion or conjecture concerning one or more populations
=sqrt((p*(1-p)/n)

28. Test for Independence
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
Prevention and appraisal costs are balanced against internal and external failure.
10 if Almost impossible to detect
Represents the behavior of a process

29. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
The US national quality award.
The gap between what management thinks customers want and what customers really want.
It looks to minimize the probability of a failure - or to minimize its effects
5%

30. What is written on the "spines" of a fishbone diagram?
Causes that lead to a particular effect.
Shifts - Trends - Repeating patterns - Correlation with known events
Linearity - normality - homoscedasticity - independence.
The gap between what is promised and what is delivered.

31. Who developed the fishbone diagram?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Kaoru Ishikawa.
Large enough to find two of the attribute - on average.
95%

32. What is DMADV?
Large enough to find two of the attribute - on average.
Not necessarily.
Define - measure - analyze - design - verify.
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

33. What is a Gage R&R?
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).
Lean (or JIT).
Mean time to failure.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

34. Definition of Interaction
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Rapid improvement process.
10 if Almost impossible to detect
An assertion or conjecture concerning one or more populations

35. Uses of regression - Control
Waste.
To obtain a certain desirable outcome from the process
Rapid improvement 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).

36. 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.
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:
Rapid improvement process.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

37. The Test Statistic (TS)
Speed - courtesy - competence - and ease of repair.
A random variable that summarizes the information from the sample(s).
An assertion or conjecture concerning one or more populations
Mean time to replacement.

38. Defect location check sheets
The ability of a process to consistently meet customer specifications.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Actual drawings - layouts - maps - etc which show where a defect occurs
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

39. In Juran's Cost of Quality model - which categories of costs balance which other categories?
It's good -- but it's still out of control!
Stratify a particular defect type according to logical criteria
An assertion or conjecture concerning one or more populations
Prevention and appraisal costs are balanced against internal and external failure.

40. What is a dashboard?
Sort - Set in Order - Shine - Standardize - Sustain
A tool that shows performance along key dimensions all at once.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
99.73%

41. What are the 5 Ss?
No -- only if the process is also capable.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Sort - Set in Order - Shine - Standardize - Sustain
The gap between what management thinks customers want and what customers really want.

42. What type of risk is associated with Type II Error?
Attribute
F_alpha - df(tr) - df (error)
68%
Consumer risk.

43. To what does the Six in Six Sigma relate?
Hold all input variables constant except one. Observe the response as you vary the single input.
= 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
They move closer to the center line.
The target number of standard deviations from the mean for specifications.

44. In the Service Quality Gap Model - what is Gap 2?
F_alpha - df(tr) - df (error)
The gap between what management thinks customers want and the process specifications.
Fractional factorial designs (orthogonal arrays)
Lean (or JIT).

45. Taguchi's experimental designs are of this type.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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
95%
Fractional factorial designs (orthogonal arrays)

46. In the Service Quality Gap Model - what is Gap 1?
A scatterplot.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Supplier - input - process - output - customer.
The gap between what management thinks customers want and what customers really want.

47. Regression Analysis
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
It's good -- but it's still out of control!
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:
Is the way in which the failure is manifested.

48. Advantages of DOE
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
No -- the variation also has to be random and "expected."
To be a member of a Six Sigma project team.
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

49. What does DMAIC stand for?
F_alpha - df(tr) - df (error)
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
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
Define - measure - analyze - improve - control.

50. What is Type 1 Error?
Concluding there has been an effect/change when there has not.
No -- only if the process is also capable.
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