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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. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
It's good -- but it's still out of control!
95%
=sqrt((p*(1-p)/n)
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

2. List two components of external failure.
Prevention and appraisal costs are balanced against internal and external failure.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
0.9^3 or 72.9%
An assertion or conjecture concerning one or more populations

3. What is a histogram?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Fishbone - cause-and-effect diagram.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

4. List two components of prevention cost.
A descending order-sorted bar chart with a cumulative percentage line.
Mistake-proofing.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
A tool that shows the physical flows through a space.

5. FMEA
Studying firms with the best performance in a particular area.
A tool that shows the physical flows through a space.
Variable.
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

6. Does it ever make sense to accept a job when a process is incapable?
Mean time to replacement.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
No -- if it is not the same - it can only be worse!

7. What inventory approach contributes to process quality by "lowering the river to find the rocks?"
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Lean (or JIT).
A time series plot.
QFD

8. What is muda
Blame.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Waste.
The degree to which a product meets pre-established standards.

9. What do you do when a process is out of control?
Look for the assignable cause of non-random variation.
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 degree to which a product meets pre-established standards.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

10. What are the 5 Ss?
The manager in charge of a process being improved in a Six Sigma project.
Deming.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Sort - Set in Order - Shine - Standardize - Sustain

11. In a regression - what does the coefficient of the intercept tell you
Taguchi
Inventory = throughput x flow time.
What the value of the dependent variable is when the independent variable is zero.
No -- if it is not the same - it can only be worse!

12. Define perceived quality (Garvin's framework).
Shifts - Trends - Repeating patterns - Correlation with known events
The US national quality award.
Brand image.
99.73%

13. Uses of regression
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
Is the way in which the failure is manifested.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
= 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

14. What is the role of a master black belt?
To mentor/coach (and sometimes train) black belts.
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 manager in charge of a process being improved in a Six Sigma project.
Used to create frequency distribution tally sheets

15. 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.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Studying firms with the best performance in a particular area.

16. Residual
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Large enough to find two of the attribute - on average.
Lower skill requirements - faster - less chance for error.
Speed - courtesy - competence - and ease of repair.

17. List two appraisal costs.
To manage the Six Sigma project.
Fishbone - cause-and-effect diagram.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Not necessarily.

18. Why do you need two control charts for variables SPC?
= 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
Because the mean and standard deviation are independent of each other.
The secondary characteristics of a product; "bells and whistles."
The gap between what customers expect and the service they receive.

19. If a three-stage process has 90% yields at each stage - what is the overall yield?
Controlling quality at the source.
0.9^3 or 72.9%
Large enough to find two of the attribute - on average.
Mean time to replacement.

20. Which quality guru developed the concept of loss to society?
Causes that lead to a particular effect.
Stratify a particular defect type according to logical criteria
Taguchi
Defects Per Million Opportunities

21. The data points on an SPC p-chart of defective percent plot below the mean. Is this good or bad?

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22. In the Service Quality Gap Model - what is Gap 4?
The gap between what is promised and what is delivered.
Variable.
The ability of a process to consistently meet customer specifications.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

23. Define features.
The secondary characteristics of a product; "bells and whistles."
10 if Almost impossible to detect
A descending order-sorted bar chart with a cumulative percentage line.
Upper control limit.

24. When is Cpk used?
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.
Variable.
To do a capability study for a non-centered process.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

25. What does the abbreviation UCL stand for?
Look for the assignable cause of non-random variation.
Upper control limit.
Supplier - input - process - output - customer.
Shows the temporal flow of activities in a project network.

26. Define conformance quality.
Shifts - Trends - Repeating patterns - Correlation with known events
The degree to which a product meets pre-established standards.
Taguchi
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

27. Affinity Diagrams
Prevention and appraisal costs are balanced against internal and external failure.
Outside.
Organize ideas into meaningful categories by recognizing their underlying similarity
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

28. What does a project prioritization matrix do?
Fractional factorial designs (orthogonal arrays)
Failure Modes and Effects Analysis
Actual drawings - layouts - maps - etc which show where a defect occurs
Assigns scores to weighted criteria for each project under consideration.

29. To what does the Six in Six Sigma relate?
The target number of standard deviations from the mean for specifications.
The degree to which a product meets pre-established standards.
=sqrt((p*(1-p)/n)
Scrap - rework - retest - downtime - yield losses - disposition costs.

30. One factor at a time (OFAT)
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Hold all input variables constant except one. Observe the response as you vary the single input.
99.73%
Critical to quality.

31. Taguchi's experimental designs are of this type.
The House of Quality.
Brand image.
Fractional factorial designs (orthogonal arrays)
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

32. Affinity Diagrams
Outside.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
What the value of the dependent variable is when the independent variable is zero.
0.9^3 or 72.9%

33. What is a Gantt chart?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
A tool that shows performance along key dimensions all at once.
Shows the temporal flow of activities in a project network.

34. Cause and Effect Diagrams
Method developed by Ishikawa to graphically display the causes of any given problem
Pleasing to the senses.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Attribute.

35. In the Service Quality Gap Model - what is Gap 2?
Fractional factorial designs (orthogonal arrays)
A descending order-sorted bar chart with a cumulative percentage line.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
The gap between what management thinks customers want and the process specifications.

36. Regression Analysis
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The House of Quality.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Large enough to find two of the attribute - on average.

37. What is process capability?
The ability of a process to consistently meet customer specifications.
Initiated before or at design concept finalization
Method developed by Ishikawa to graphically display the causes of any given problem
Through producer/consumer negotiation.

38. PFMEA
Before production starts
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Actual drawings - layouts - maps - etc which show where a defect occurs
To be a member of a Six Sigma project team.

39. What are two other names for an Ishikawa diagram?
Blame.
To be a member of a Six Sigma project team.
Fishbone - cause-and-effect diagram.
It's good -- but it's still out of control!

40. What is a spaghetti diagram?
The manager in charge of a process being improved in a Six Sigma project.
A tool that shows the physical flows through a space.
Brand image.
10 if Almost impossible to detect

41. TWO-DIMENTIONAL SCATTER PLOT
Initiated before or at design concept finalization
Can't tell without a Range chart.
No -- if it is not the same - it can only be worse!
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

42. Process occurance ranking
Outside.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
Actual drawings - layouts - maps - etc which show where a defect occurs
A descending order-sorted bar chart with a cumulative percentage line.

43. What percentage of a normal distribution lies above the mean?
No -- the variation also has to be random and "expected."
Lean (or JIT).
Defects Per Million Opportunities
50%

44. What is poka yoke?
To obtain a certain desirable outcome from the process
Concluding there has not been an effect/change when there has.
Financial - customer - internal process - innovation and learning.
Mistake-proofing.

45. Who first studied randomness in industrial processes
Because the mean and standard deviation are independent of each other.
Walter A. Shewhart
Lower control limit.
The target number of standard deviations from the mean for specifications.

46. Detection Criteria Ranking
10 if Almost impossible to detect
The House of Quality.
QFD
An interaction is defined as a dependence relationship between the response and the levels of two or more variables

47. Daniel Test
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:
68%
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
Through producer/consumer negotiation.

48. What quality tool formally incorporates the voice of the customer?
Observed variation in response is caused by the input
QFD
A tool that shows where there is waste in a process.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

49. What is the formula for standard deviation?
Central Limit Theorem
Before production starts
=sqrt(Σ(x-x-bar)^2)/(n-1))
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

50. Define performance quality.
The primary operating characteristics of a product.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
The gap between what management thinks customers want and what customers really want.
The ratio of outputs to inputs; 1-scrap.