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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 product reliability.
Lower control limit.
0.9^3 or 72.9%
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.
Mean time to failure.

2. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Sampling for SPC is done real time.
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
Walter A. Shewhart
The cycle time required to meet demand.

3. List two components of prevention cost.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
The cycle time required to meet demand.
Supplier - input - process - output - customer.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.

4. Where should specifications fall in relation to ± 3 sigma for the process in order for a process to be capable.
Because the mean and standard deviation are independent of each other.
No -- only if the process is also capable.
The number of standard deviations some value is from the mean.
Outside.

5. What does a project prioritization matrix do?
The gap between specifications and how service is performed.
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:
Assigns scores to weighted criteria for each project under consideration.
Studying firms with the best performance in a particular area.

6. List Garvin's eight dimensions of product quality.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Scrap - rework - retest - downtime - yield losses - disposition costs.
A random variable that summarizes the information from the sample(s).
Represents the behavior of a process

7. Why do you need two control charts for variables SPC?
Rapid improvement process.
5%
Sampling for SPC is done real time.
Because the mean and standard deviation are independent of each other.

8. What does the abbreviation LCL stand for?
Is the consequence of the failure.
Lower control limit.
Is what induces the failure
Controlling quality at the source.

9. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Central Limit Theorem
Lower control limit.
0.9^3 or 72.9%
Conformance to specifications.

10. Define durability.
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
Mean time to replacement.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

11. If a Cp shows that a process is not capable - should you calculate Cpk?
Is the way in which the failure is manifested.
No -- if it is not the same - it can only be worse!
Look for the assignable cause of non-random variation.
A scatterplot.

12. In the Service Quality Gap Model - what is Gap 5?
The gap between what customers expect and the service they receive.
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
Defects Per Million Opportunities
It's good -- but it's still out of control!

13. In a regression - what does the standard error of the estimate tell you?
Shows the temporal flow of activities in a project network.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

14. Who first studied randomness in industrial processes
Lower skill requirements - faster - less chance for error.
Walter A. Shewhart
Conformance to specifications.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

15. ANOVA

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16. A process is operating "in control." Does this mean the customer's requirements are met?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
No -- only if the process is also capable.
A diagram that shows the relationships between activities in a project network.
Prevention and appraisal costs are balanced against internal and external failure.

17. Failure cause
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
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 what induces the 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

18. What is poka yoke?
Mistake-proofing.
Waste.
Define - measure - analyze - improve - control.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

19. In a Z table - what is Z?
A time series plot.
Initiated before or at design concept finalization
Scrap - rework - retest - downtime - yield losses - disposition costs.
The number of standard deviations some value is from the mean.

20. Define features.
To mentor/coach (and sometimes train) black belts.
The secondary characteristics of a product; "bells and whistles."
Can't tell without a Range chart.
The target number of standard deviations from the mean for specifications.

21. What is a Gage R&R?
Deming.
Is the way in which the failure is manifested.
Walter A. Shewhart
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).

22. For what is an x-bar chart used?
What the value of the dependent variable is when the independent variable is zero.
Stratify a particular defect type according to logical criteria
The manager in charge of a process being improved in a Six Sigma project.
To monitor a process when measurement by variables is used.

23. Define conformance quality.
The degree to which a product meets pre-established standards.
The cycle time required to meet demand.
Consumer risk.
Lean is waste reduction - Six Sigma is variation reduction.

24. What are the four perspectives of the Balanced Scorecard?
Financial - customer - internal process - innovation and learning.
Attribute
Conformance to specifications.
The primary operating characteristics of a product.

25. Your production process meets customer specifications. Is your process in control?
X-bar-bar
Not necessarily.
Controlling quality at the source.
The ratio of outputs to inputs; 1-scrap.

26. What is muda
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
To manage the Six Sigma project.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Waste.

27. Does it ever make sense to accept a job when a process is incapable?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
A tool that shows performance along key dimensions all at once.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Variable.

28. PFMEA
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).
Before production starts
Can't tell without a Range chart.

29. What is the role of a master black belt?
Not necessarily.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
To mentor/coach (and sometimes train) black belts.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.

30. What quality tool formally incorporates the voice of the customer?
Someone who is consistently against virtually everything.
QFD
No -- if it is not the same - it can only be worse!
A diagram that shows the relationships between activities in a project network.

31. 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.
Consumer risk.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Hold all input variables constant except one. Observe the response as you vary the single input.

32. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Sampling for SPC is done real time.
X-bar-bar
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Prevention and appraisal costs are balanced against internal and external failure.

33. 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
Kaoru Ishikawa.
The gap between specifications and how service is performed.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

34. In a regression - what does the coefficient of the intercept tell you
Controlling quality at the source.
Sort - Set in Order - Shine - Standardize - Sustain
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
What the value of the dependent variable is when the independent variable is zero.

35. Detection Criteria Ranking
Defects Per Million Opportunities
10 if Almost impossible to detect
Attribute
Outside.

36. One factor at a time (OFAT)
Attribute.
Speed - courtesy - competence - and ease of repair.
Hold all input variables constant except one. Observe the response as you vary the single input.
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

37. Failure Mode
Stratify a particular defect type according to logical criteria
Is the way in which the failure is manifested.
It looks to minimize the probability of a failure - or to minimize its effects
No -- the variation also has to be random and "expected."

38. What is the role of a black belt?
Variable.
To manage the Six Sigma project.
68%
Through producer/consumer negotiation.

39. What is Value Stream Mapping?
Before production starts
0.9^3 or 72.9%
Method developed by Ishikawa to graphically display the causes of any given problem
A tool that shows where there is waste in a process.

40. Define takt time.
The cycle time required to meet demand.
Prevention - appraisal - internal failure - external failure.
Define - measure - analyze - improve - control.
The gap between what customers expect and the service they receive.

41. Who developed the fishbone diagram?
Lean is waste reduction - Six Sigma is variation reduction.
Outside.
Kaoru Ishikawa.
To do a capability study for a non-centered process.

42. Histogram by Hand
Prevention - appraisal - internal failure - external failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
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
Upper control limit.

43. 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.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
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
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

44. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
Variable.
Observed variation in response is caused by the input
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
The gap between what is promised and what is delivered.

45. What happens to control limits on an SPC chart when sample size is increased?
Speed - courtesy - competence - and ease of repair.
To be a member of a Six Sigma project team.
They move closer to the center line.
Hold all input variables constant except one. Observe the response as you vary the single input.

46. Which quality guru developed the concept of loss to society?
Taguchi
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
p-bar - the long-run percent defective.
Shows the temporal flow of activities in a project network.

47. What is FMEA?
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Mistake-proofing.
Failure Modes and Effects Analysis
A random variable that summarizes the information from the sample(s).

48. When is Cpk used?
A scatterplot.
Variable.
To do a capability study for a non-centered process.
To obtain a certain desirable outcome from the process

49. What is Kaizen?
Is the consequence of the failure.
Rapid improvement process.
Causes that lead to a particular effect.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

50. List two components of external failure.
No -- if it is not the same - it can only be worse!
Taguchi
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.