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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. In the Service Quality Gap Model - what is Gap 2?
The gap between what management thinks customers want and the process specifications.
50%
QFD
A tool that shows where there is waste in a process.

2. How does Juran define quality?
Mistake-proofing.
The US national quality award.
The gap between what management thinks customers want and what customers really want.
Fitness for use.

3. FMEA
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
Kaoru Ishikawa.
It looks to minimize the probability of a failure - or to minimize its effects

4. Your production process meets customer specifications. Is your process in control?
Supplier - input - process - output - customer.
Before production starts
Not necessarily.
Taguchi

5. What is the Deming Prize?
Rapid improvement process.
Is what induces the failure
= 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
The Japanese national quality award.

6. Who first studied randomness in industrial processes
Actual drawings - layouts - maps - etc which show where a defect occurs
Walter A. Shewhart
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.
F_alpha - df(tr) - df (error)

7. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
The degree to which a product meets pre-established standards.
5%
99.73%
Financial - customer - internal process - innovation and learning.

8. Define features.
Organize ideas into meaningful categories by recognizing their underlying similarity
The secondary characteristics of a product; "bells and whistles."
The Japanese national quality award.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

9. Defect location check sheets
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Deming.
Actual drawings - layouts - maps - etc which show where a defect occurs

10. When is Cpk used?
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).
Prevention and appraisal costs are balanced against internal and external failure.
To do a capability study for a non-centered process.
Mean time to replacement.

11. Define yield.
The ratio of outputs to inputs; 1-scrap.
No -- only if the process is also capable.
The US national quality award.
The degree to which a product meets pre-established standards.

12. What type of risk is associated with Type 1 Error?
50%
Taguchi
Producer risk.
Not necessarily.

13. Simple Regression Analysis (one factor regression model)
Fewer good units to sell - increased variable cost/unit.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
= 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
To mentor/coach (and sometimes train) black belts.

14. Define takt time.
The cycle time required to meet demand.
Concluding there has been an effect/change when there has not.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
To monitor a process when measurement by variables is used.

15. What does a project prioritization matrix do?
Assigns scores to weighted criteria for each project under consideration.
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
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
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

16. What is a run chart?
Before production starts
A time series plot.
Define - measure - analyze - design - verify.
Critical to quality.

17. Taguchi's experimental designs are of this type.
Fractional factorial designs (orthogonal arrays)
Because the mean and standard deviation are independent of each other.
Concluding there has not been an effect/change when there has.
Prevention - appraisal - internal failure - external failure.

18. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
Causes that lead to a particular effect.
Organize ideas into meaningful categories by recognizing their underlying similarity
Not necessarily.
100%

19. Disadvantages of DOE

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20. What is poka yoke?
Mistake-proofing.
The gap between what management thinks customers want and what customers really want.
Before production starts
Lower skill requirements - faster - less chance for error.

21. In a regression - what does the p value of F tell you?
The secondary characteristics of a product; "bells and whistles."
How likely it is to have an F statistic of that value if there really is no relationship between the dependent variable and the independent variable(s).
To monitor a process when measurement by variables is used.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.

22. What does DMAIC stand for?
The degree to which a product meets pre-established standards.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Define - measure - analyze - improve - control.
Inventory = throughput x flow time.

23. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Technical quality is the "what" of the service; functional quality is the "how."
Attribute.
Pleasing to the senses.
Conformance to specifications.

24. Design of Experiments (DOE) approach
Is what induces the failure
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
0.9^3 or 72.9%
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

25. Define performance quality.
The primary operating characteristics of a product.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

26. What happens to control limits on an SPC chart when sample size is increased?
Lean is waste reduction - Six Sigma is variation reduction.
They move closer to the center line.
=sqrt((p*(1-p)/n)
Initiated before or at design concept finalization

27. What are the four categories of costs in Juran's framework?
Prevention - appraisal - internal failure - external failure.
Sampling for SPC is done real time.
The manager in charge of a process being improved in a Six Sigma project.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.

28. What is DPMO?
5%
Defects Per Million Opportunities
The number of standard deviations some value is from the mean.
X-bar-bar

29. What are two other names for an Ishikawa diagram?
A tool that shows where there is waste in a process.
Blame.
Fishbone - cause-and-effect diagram.
Producer risk.

30. Presence of interaction effect
Financial - customer - internal process - innovation and learning.
Lower skill requirements - faster - less chance for error.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
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.

31. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
Kaoru Ishikawa.
Not necessarily.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
68%

32. F value
F_alpha - df(tr) - df (error)
To monitor a process when measurement by attribute is used.
Hold all input variables constant except one. Observe the response as you vary the single input.
=sqrt((p*(1-p)/n)

33. Histogram by Hand
Inventory = throughput x flow time.
= 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
Pleasing to the senses.
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

34. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Sampling for SPC is done real time.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
The primary operating characteristics of a product.
Initiated before or at design concept finalization

35. Test for Independence
How likely it is to have an F statistic of that value if there really is no relationship between the dependent variable and the independent variable(s).
Waste.
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
Sampling for SPC is done real time.

36. Which type of SPC measurement is more precise - variable or attribute?
= 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
The degree to which a product meets pre-established standards.
Variable.
Stratify a particular defect type according to logical criteria

37. ANOVA

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38. Who developed the fishbone diagram?
Taguchi
Kaoru Ishikawa.
Prevention - appraisal - internal failure - external failure.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

39. Definition of Interaction
Look for the assignable cause of non-random variation.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Variable.
Attribute

40. Define conformance quality.
The degree to which a product meets pre-established standards.
A tool that shows performance along key dimensions all at once.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.

41. List two components of internal failure.
A tool that shows performance along key dimensions all at once.
Scrap - rework - retest - downtime - yield losses - disposition costs.
F_alpha - df(tr) - df (error)
The ability of a process to consistently meet customer specifications.

42. FMEA
Attribute.
The cycle time required to meet demand.
Represents the behavior of a 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

43. Non-random patterns (Run Charts)
A brainstorming tool that shows the connections between ideas.
No -- if it is not the same - it can only be worse!
Shifts - Trends - Repeating patterns - Correlation with known events
Financial - customer - internal process - innovation and learning.

44. What is written on the "spines" of a fishbone diagram?
Shows the temporal flow of activities in a project network.
The US national quality award.
Financial - customer - internal process - innovation and learning.
Causes that lead to a particular effect.

45. In Juran's Cost of Quality model - which categories of costs balance which other categories?
The primary operating characteristics of a product.
Prevention and appraisal costs are balanced against internal and external failure.
F_alpha - df(tr) - df (error)
Before production starts

46. One factor at a time (OFAT)
A brainstorming tool that shows the connections between ideas.
Hold all input variables constant except one. Observe the response as you vary the single input.
The gap between specifications and how service is performed.
Waste.

47. Define perceived quality (Garvin's framework).
Brand image.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
5%
Linearity - normality - homoscedasticity - independence.

48. What is Jidoka?
Prevention - appraisal - internal failure - external failure.
Organize ideas into meaningful categories by recognizing their underlying similarity
Can't tell without a Range chart.
Controlling quality at the source.

49. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
A diagram that shows the relationships between activities in a project network.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
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

50. Affinity Diagrams
Sort - Set in Order - Shine - Standardize - Sustain
=sqrt(Σ(x-x-bar)^2)/(n-1))
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Actual drawings - layouts - maps - etc which show where a defect occurs