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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. When is Cpk used?
To do a capability study for a non-centered process.
No -- the variation also has to be random and "expected."
Controlling quality at the source.
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).

2. What does DMAIC stand for?
Define - measure - analyze - improve - control.
A time series plot.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Define - measure - analyze - design - verify.

3. List two components of internal failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Observed variation in response is caused by the input
Lean is waste reduction - Six Sigma is variation reduction.
= 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

4. In a regression - what does the p value of F tell you?
A tool that shows where there is waste in a process.
To monitor a process when measurement by attribute is used.
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).
Observed variation in response is caused by the input

5. Risk Priority Number RPN
Inventory = throughput x flow time.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
The House of Quality.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is

6. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
The number of standard deviations some value is from the mean.
The gap between what customers expect and the service they receive.
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.

7. A process is operating "in control." Does this mean the customer's requirements are met?
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Prevention - appraisal - internal failure - external failure.
No -- only if the process is also capable.
Technical quality is the "what" of the service; functional quality is the "how."

8. What is Kaizen?
Workers - machines - materials.
Rapid improvement process.
The ratio of outputs to inputs; 1-scrap.
Because the mean and standard deviation are independent of each other.

9. For your SPC sample you weigh bags of potatoes. Is this variable or attribute SPC?
A descending order-sorted bar chart with a cumulative percentage line.
QFD
Variable.
Define - measure - analyze - improve - control.

10. To what does the Six in Six Sigma relate?
To be a member of a Six Sigma project team.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Central Limit Theorem
The target number of standard deviations from the mean for specifications.

11. What is the formula for standard deviation?
=sqrt(Σ(x-x-bar)^2)/(n-1))
A tool that shows the physical flows through a space.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
A time series plot.

12. If a three-stage process has 90% yields at each stage - what is the overall yield?
Organize ideas into meaningful categories by recognizing their underlying similarity
A random variable that summarizes the information from the sample(s).
0.9^3 or 72.9%
The number of standard deviations some value is from the mean.

13. What happens to control limits on an SPC chart when sample size is increased?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Mistake-proofing.
They move closer to the center line.
Look for the assignable cause of non-random variation.

14. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
0.9^3 or 72.9%
99.73%
Deming.
Is the consequence of the failure.

15. What is the role of a green belt?
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 gap between what is promised and what is delivered.
Concluding there has not been an effect/change when there has.
To be a member of a Six Sigma project team.

16. Stratified defect check sheets
Stratify a particular defect type according to logical criteria
An assertion or conjecture concerning one or more populations
Organize ideas into meaningful categories by recognizing their underlying similarity
No -- only if the process is also capable.

17. Name the structure associated with Quality Function Deployment.
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
Define - measure - analyze - design - verify.
The House of Quality.
100%

18. If a Cp shows that a process is not capable - should you calculate Cpk?
3.4 (assuming 1.5 sigma shift in the mean)
Waste.
No -- if it is not the same - it can only be worse!
Is what induces the failure

19. What are the four perspectives of the Balanced Scorecard?
Financial - customer - internal process - innovation and learning.
Because the mean and standard deviation are independent of each other.
It's good -- but it's still out of control!
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).

20. Taguchi's experimental designs are of this type.
Fractional factorial designs (orthogonal arrays)
Large enough to find two of the attribute - on average.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

21. Why do you need two control charts for variables SPC?
Fractional factorial designs (orthogonal arrays)
Because the mean and standard deviation are independent of each other.
Fewer good units to sell - increased variable cost/unit.
To monitor a process when measurement by attribute is used.

22. Detection Criteria Ranking
Defects Per Million Opportunities
They move closer to the center line.
10 if Almost impossible to detect
Producer risk.

23. What is a CAVE man?
Someone who is consistently against virtually everything.
Is what induces the failure
Sort - Set in Order - Shine - Standardize - Sustain
= 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

24. What is the formula for the standard deviation of a proportion?
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
=sqrt((p*(1-p)/n)
Lean is waste reduction - Six Sigma is variation reduction.
Different types of defects are listed (used for Pareto chart)

25. If you have calculated a Cpk - should you also calculate a Cp?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper

26. Histogram by Hand
A tool that shows where there is waste in a process.
Failure Modes and Effects Analysis
Used to create frequency distribution tally sheets
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

27. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
Upper control limit.
The secondary characteristics of a product; "bells and whistles."
Attribute
A diagram that shows the relationships between activities in a project network.

28. What size should samples be for attribute SPC?
Large enough to find two of the attribute - on average.
Is the consequence of the failure.
Defects Per Million Opportunities
The ratio of outputs to inputs; 1-scrap.

29. What do you do when a process is out of control?
Look for the assignable cause of non-random variation.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
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
No -- only if the process is also capable.

30. Test for Independence
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
Shows the temporal flow of activities in a project network.
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
99.73%

31. When yields decrease - what are the two effects on contribution?
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Shifts - Trends - Repeating patterns - Correlation with known events
= 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
Fewer good units to sell - increased variable cost/unit.

32. What is a Gage R&R?
Represents the behavior of a process
Technical quality is the "what" of the service; functional quality is the "how."
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
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).

33. For what is an x-bar chart used?
To monitor a process when measurement by variables is used.
50%
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
The gap between what management thinks customers want and the process specifications.

34. Non-random patterns (Run Charts)
Shifts - Trends - Repeating patterns - Correlation with known events
Mistake-proofing.
The House of Quality.
Variable.

35. Affinity Diagrams
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Supplier - input - process - output - customer.
A time series plot.
Method developed by Ishikawa to graphically display the causes of any given problem

36. Statistical Hypothesis
3.4 (assuming 1.5 sigma shift in the mean)
Upper control limit.
A time series plot.
An assertion or conjecture concerning one or more populations

37. Complete this quality phrase: 'Fix the process - not the _____.'
Studying firms with the best performance in a particular area.
The cycle time required to meet demand.
Blame.
Mean time to replacement.

38. Process occurance ranking
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
No -- if it is not the same - it can only be worse!
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

39. Regression Analysis
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.
An assertion or conjecture concerning one or more populations
Sort - Set in Order - Shine - Standardize - Sustain
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

40. What is written on the "spines" of a fishbone diagram?
Before production starts
To manage the Six Sigma project.
Causes that lead to a particular effect.
Studying firms with the best performance in a particular area.

41. What is the 5S model?
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.
No -- only if the process is also capable.
Concluding there has not been an effect/change when there has.
Method developed by Ishikawa to graphically display the causes of any given problem

42. Defect check sheets
Workers - machines - materials.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
Different types of defects are listed (used for Pareto chart)
p-bar - the long-run percent defective.

43. Design of Experiments (DOE) approach
Concluding there has not been an effect/change when there has.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Mean time to failure.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

44. What is the center line of a p-chart?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
p-bar - the long-run percent defective.
Producer risk.
To monitor a process when measurement by variables is used.

45. If you can only collect categorical data - what type of SPC charting can you do?
A brainstorming tool that shows the connections between ideas.
Consumer risk.
Attribute.
Fractional factorial designs (orthogonal arrays)

46. What does Crosby say about benchmarking?
The manager in charge of a process being improved in a Six Sigma project.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
No -- only if the process is also capable.
Stratify a particular defect type according to logical criteria

47. In a Z table - what is Z?
The number of standard deviations some value is from the mean.
Fishbone - cause-and-effect diagram.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
No -- the variation also has to be random and "expected."

48. What is Type 1 Error?
Variable.
No -- the variation also has to be random and "expected."
Walter A. Shewhart
Concluding there has been an effect/change when there has not.

49. In the Service Quality Gap Model - what is Gap 3?
The gap between specifications and how service is performed.
Stratify a particular defect type according to logical criteria
A tool that shows performance along key dimensions all at once.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

50. Who developed the fishbone diagram?
0.9^3 or 72.9%
Because the mean and standard deviation are independent of each other.
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
Kaoru Ishikawa.