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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. Define benchmarking.
Can't tell without a Range chart.
Variable.
Studying firms with the best performance in a particular area.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

2. Failure Mode
Outside.
Consumer risk.
Observed variation in response is caused by the input
Is the way in which the failure is manifested.

3. Your production process meets customer specifications. Is your process in control?
Is the way in which the failure is manifested.
Mean time to failure.
Brand image.
Not necessarily.

4. What does the abbreviation UCL stand for?
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Upper control limit.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
A brainstorming tool that shows the connections between ideas.

5. Name the structure associated with Quality Function Deployment.
Define - measure - analyze - improve - control.
A descending order-sorted bar chart with a cumulative percentage line.
The House of Quality.
An assertion or conjecture concerning one or more populations

6. Advantages of DOE
Used to create frequency distribution tally sheets
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
Scrap - rework - retest - downtime - yield losses - disposition costs.
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

7. What is DPMO?
Failure Modes and Effects Analysis
Large enough to find two of the attribute - on average.
No -- if it is not the same - it can only be worse!
Defects Per Million Opportunities

8. What are the four categories of costs in Juran's framework?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
To monitor a process when measurement by attribute is used.
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
Prevention - appraisal - internal failure - external failure.

9. Failure effect
Walter A. Shewhart
Is the consequence of the failure.
Inventory = throughput x flow time.
Can't tell without a Range chart.

10. Define perceived quality (Garvin's framework).
The ability of a process to consistently meet customer specifications.
Brand image.
A tool that shows where there is waste in a process.
Is the way in which the failure is manifested.

11. Disadvantages of DOE

12. 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.
Mistake-proofing.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Lower skill requirements - faster - less chance for error.

13. Test for constant variance
Central Limit Theorem
Upper control limit.
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.
Because the mean and standard deviation are independent of each other.

14. Process check sheets
Used to create frequency distribution tally sheets
Define - measure - analyze - improve - control.
The House of Quality.
=sqrt(Σ(x-x-bar)^2)/(n-1))

15. What is the role of a green belt?
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.
Waste.
Sampling for SPC is done real time.
To be a member of a Six Sigma project team.

16. Which quality guru developed the concept of loss to society?
The gap between what customers expect and the service they receive.
Controlling quality at the source.
Taguchi
Different types of defects are listed (used for Pareto chart)

17. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
Consumer risk.
Linearity - normality - homoscedasticity - independence.
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.

18. What is an affinity diagram?
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
A brainstorming tool that shows the connections between ideas.
Initiated before or at design concept finalization
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

19. What are the four perspectives of the Balanced Scorecard?
Outside.
Financial - customer - internal process - innovation and learning.
Taguchi
A tool that shows the physical flows through a space.

20. What graphical tool is used to show the relationship between two numerical variables?
Variable.
0.9^3 or 72.9%
A scatterplot.
Studying firms with the best performance in a particular area.

21. Does it ever make sense to accept a job when a process is incapable?
Brand image.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
To obtain a certain desirable outcome from the process
Define - measure - analyze - improve - control.

22. Statistical Hypothesis
An assertion or conjecture concerning one or more populations
Brand image.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Concluding there has not been an effect/change when there has.

23. Pareto Analysis
No -- only if the process is also capable.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Concluding there has been an effect/change when there has not.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

24. List two appraisal costs.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
X-bar-bar
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
=sqrt((p*(1-p)/n)

25. List Garvin's eight dimensions of product quality.
F_alpha - df(tr) - df (error)
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
5%
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

26. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
100%
A tool that shows performance along key dimensions all at once.
Assigns scores to weighted criteria for each project under consideration.
The gap between what management thinks customers want and what customers really want.

27. ANOVA

28. What is Type II Error?
= 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
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Concluding there has not been an effect/change when there has.
No -- the variation also has to be random and "expected."

29. If a three-stage process has 90% yields at each stage - what is the overall yield?
0.9^3 or 72.9%
The US national quality award.
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).
Reliability - Assurance - Responsiveness - Tangibles - Empathy

30. Residual(eij)
= yij - y(bar)i --> value minus sum of that treatment (of row)
0.9^3 or 72.9%
Central Limit Theorem
Not necessarily.

31. What does a project prioritization matrix do?
Assigns scores to weighted criteria for each project under consideration.
10 if Almost impossible to detect
Concluding there has not been an effect/change when there has.
Taguchi

32. 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?
False - because each machine will have different natural tolerances.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
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.
Concluding there has been an effect/change when there has not.

33. Failure cause
Is what induces the failure
Central Limit Theorem
Inventory = throughput x flow time.
Taguchi

34. What is a network diagram?
Observed variation in response is caused by the input
Prevention and appraisal costs are balanced against internal and external failure.
A diagram that shows the relationships between activities in a project network.
X-bar-bar

35. List two components of internal failure.
Linearity - normality - homoscedasticity - independence.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Attribute
Defects Per Million Opportunities

36. DOE
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Variable.
Financial - customer - internal process - innovation and learning.
The gap between what management thinks customers want and the process specifications.

37. Based on what principal can we use the normal distribution assumptions for SPC?
Studying firms with the best performance in a particular area.
Central Limit Theorem
p-bar - the long-run percent defective.
Shifts - Trends - Repeating patterns - Correlation with known events

38. FMEA
A tool that shows where there is waste in a process.
Rapid improvement process.
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 primary operating characteristics of a product.

39. In the Service Quality Gap Model - what is Gap 4?
To obtain a certain desirable outcome from the process
A scatterplot.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
The gap between what is promised and what is delivered.

40. Define takt time.
The primary operating characteristics of a product.
Is what induces the failure
The cycle time required to meet demand.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

41. What is the center line of a p-chart?
To manage the Six Sigma project.
Technical quality is the "what" of the service; functional quality is the "how."
p-bar - the long-run percent defective.
Stratify a particular defect type according to logical criteria

42. In the Service Quality Gap Model - what is Gap 5?
Assigns scores to weighted criteria for each project under consideration.
Supplier - input - process - output - customer.
The gap between what customers expect and the service they receive.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

43. How are LQL and AQL determined in an acceptance sampling plan?
The gap between what customers expect and the service they receive.
No -- the variation also has to be random and "expected."
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Through producer/consumer negotiation.

44. F value
F_alpha - df(tr) - df (error)
It looks to minimize the probability of a failure - or to minimize its effects
Rapid improvement process.
Attribute

45. List two components of prevention cost.
The secondary characteristics of a product; "bells and whistles."
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Technical quality is the "what" of the service; functional quality is the "how."
No -- the variation also has to be random and "expected."

46. If a Cp shows that a process is not capable - should you calculate Cpk?
Initiated before or at design concept finalization
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
5%
No -- if it is not the same - it can only be worse!

47. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Lean is waste reduction - Six Sigma is variation reduction.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
The gap between specifications and how service is performed.
Outside.

48. In the Service Quality Gap Model - what is Gap 3?
The ability of a process to consistently meet customer specifications.
The gap between specifications and how service is performed.
95%
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

49. In a regression - what does the coefficient of the intercept tell you
No -- if it is not the same - it can only be worse!
Waste.
What the value of the dependent variable is when the independent variable is zero.
A descending order-sorted bar chart with a cumulative percentage line.

50. Define performance quality.
The primary operating characteristics of a product.
Sampling for SPC is done real time.
Through producer/consumer negotiation.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions