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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. What quality tool formally incorporates the voice of the customer?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
A brainstorming tool that shows the connections between ideas.
QFD
The gap between what is promised and what is delivered.

2. Risk Priority Number RPN
A diagram that shows the relationships between activities in a project network.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Not necessarily.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

3. What is written on the "spines" of a fishbone diagram?
It's good -- but it's still out of control!
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 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
Causes that lead to a particular effect.

4. In the Service Quality Gap Model - what is Gap 1?
The gap between what management thinks customers want and what customers really want.
Shows the temporal flow of activities in a project network.
To be a member of a Six Sigma project team.
Organize ideas into meaningful categories by recognizing their underlying similarity

5. How does Juran define quality?
Can't tell without a Range chart.
Fitness for use.
Consumer risk.
The ability of a process to consistently meet customer specifications.

6. Taguchi's experimental designs are of this type.
Someone who is consistently against virtually everything.
Lean is waste reduction - Six Sigma is variation reduction.
95%
Fractional factorial designs (orthogonal arrays)

7. Simple Regression Analysis (one factor regression model)
Conformance to 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
= 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
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

8. A process is operating "in control." Does this mean the customer's requirements are met?
Waste.
No -- only if the process is also capable.
A random variable that summarizes the information from the sample(s).
Observed variation in response is caused by the input

9. FMEA
Shows the temporal flow of activities in a project network.
It looks to minimize the probability of a failure - or to minimize its effects
Pleasing to the senses.
Financial - customer - internal process - innovation and learning.

10. Histogram by Hand
Lean (or JIT).
The secondary characteristics of a product; "bells and whistles."
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
Mean time to failure.

11. What is DPMO?
Prevention - appraisal - internal failure - external failure.
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
Rapid improvement process.
Defects Per Million Opportunities

12. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
The ability of a process to consistently meet customer specifications.
A diagram that shows the relationships between activities in a project network.
100%

13. In a regression - what does R-square tell you?
A time series plot.
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
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Reliability - Assurance - Responsiveness - Tangibles - Empathy

14. What is a dashboard?
A tool that shows performance along key dimensions all at once.
The Japanese national quality award.
=sqrt((p*(1-p)/n)
Define - measure - analyze - design - verify.

15. What are the four regression assumptions?
Linearity - normality - homoscedasticity - independence.
3.4 (assuming 1.5 sigma shift in the mean)
= yij - y(bar)i --> value minus sum of that treatment (of row)
If the Response vs. Levels graph if the response lines are not parallel (crossing)

16. Who is a process owner?
p-bar - the long-run percent defective.
The manager in charge of a process being improved in a Six Sigma project.
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
Conformance to specifications.

17. TWO-DIMENTIONAL SCATTER PLOT
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
The target number of standard deviations from the mean for specifications.
Can't tell without a Range chart.

18. Why do you need two control charts for variables SPC?
= yij - y(bar)i --> value minus sum of that treatment (of row)
Because the mean and standard deviation are independent of each other.
False - because each machine will have different natural tolerances.
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. When is Cpk used?
Failure Modes and Effects Analysis
To do a capability study for a non-centered process.
p-bar - the long-run percent defective.
Kaoru Ishikawa.

20. Define conformance quality.
The House of Quality.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
The degree to which a product meets pre-established standards.
Define - measure - analyze - design - verify.

21. Process check sheets
Define - measure - analyze - design - verify.
What the value of the dependent variable is when the independent variable is zero.
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
Used to create frequency distribution tally sheets

22. Define product reliability.
Blame.
Mean time to failure.
To mentor/coach (and sometimes train) black belts.
The ratio of outputs to inputs; 1-scrap.

23. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
The gap between what management thinks customers want and what customers really want.
The gap between what is promised and what is delivered.
Outside.
Variable.

24. In the Service Quality Gap Model - what is Gap 2?
The gap between what management thinks customers want and the process specifications.
Inventory = throughput x flow time.
Attribute.
Central Limit Theorem

25. Define aesthetic quality.
Represents the behavior of a process
0.9^3 or 72.9%
Pleasing to the senses.
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

26. List two components of prevention cost.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Conformance to specifications.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Someone who is consistently against virtually everything.

27. Detection Criteria Ranking
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Supplier - input - process - output - customer.
10 if Almost impossible to detect
Deming.

28. Pareto Analysis
A tool that shows the physical flows through a space.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Fractional factorial designs (orthogonal arrays)
Supplier - input - process - output - customer.

29. ANOVA

30. With Six Sigma capability - how many defects per million opportunities would you see?
Is what induces the failure
10 for Hazardous without warning 1 for none
Fractional factorial designs (orthogonal arrays)
3.4 (assuming 1.5 sigma shift in the mean)

31. You have been plotting sample means on an x-bar chart and all points indicate normal - expected variation. Is the process in control?

32. What is process capability?
Scrap - rework - retest - downtime - yield losses - disposition costs.
No -- if it is not the same - it can only be worse!
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
The ability of a process to consistently meet customer specifications.

33. What is an affinity diagram?
Inventory = throughput x flow time.
A brainstorming tool that shows the connections between ideas.
Observed variation in response is caused by the input
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

34. What is the formula for standard deviation?
Mean time to replacement.
The ratio of outputs to inputs; 1-scrap.
Shifts - Trends - Repeating patterns - Correlation with known events
=sqrt(Σ(x-x-bar)^2)/(n-1))

35. Effect ranking (Severity of the Defect)
10 for Hazardous without warning 1 for none
The ratio of outputs to inputs; 1-scrap.
Fitness for use.
= 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

36. What is the formula for the standard deviation of a proportion?
=sqrt((p*(1-p)/n)
To be a member of a Six Sigma project team.
Stratify a particular defect type according to logical criteria
Mean time to failure.

37. To what does the Six in Six Sigma relate?
Prevention - appraisal - internal failure - external failure.
Hold all input variables constant except one. Observe the response as you vary the single input.
The target number of standard deviations from the mean for specifications.
Can't tell without a Range chart.

38. Affinity Diagrams
Linearity - normality - homoscedasticity - independence.
Lower control limit.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Rapid improvement process.

39. What does DMAIC stand for?
Causes that lead to a particular effect.
Define - measure - analyze - improve - control.
Upper control limit.
= yij - y(bar)i --> value minus sum of that treatment (of row)

40. DOE
Technical quality is the "what" of the service; functional quality is the "how."
Sort - Set in Order - Shine - Standardize - Sustain
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

41. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
A tool that shows the physical flows through a space.
Used to create frequency distribution tally sheets
Variable.
F_alpha - df(tr) - df (error)

42. What does the abbreviation UCL stand for?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
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
Upper control limit.
Fitness for use.

43. List two appraisal costs.
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.
Defects Per Million Opportunities
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

44. Explain the difference between technical and functional service quality.
Not necessarily.
The ability of a process to consistently meet customer specifications.
Technical quality is the "what" of the service; functional quality is the "how."
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

45. What is Jidoka?
Controlling quality at the source.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Taguchi
QFD

46. If you can only collect categorical data - what type of SPC charting can you do?
Consumer risk.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Attribute.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

47. Which type of SPC measurement is more precise - variable or attribute?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Variable.
Supplier - input - process - output - customer.
The Japanese national quality award.

48. What are the four categories of costs in Juran's framework?
Before production starts
Observed variation in response is caused by the input
Can't tell without a Range chart.
Prevention - appraisal - internal failure - external failure.

49. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Mean time to failure.
Consumer risk.
Used to create frequency distribution tally sheets
Conformance to specifications.

50. What is a Gage R&R?
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
Is the consequence of the failure.
No -- only if the process is also capable.
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).