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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. Why do you need two control charts for variables SPC?
Because the mean and standard deviation are independent of each other.
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).
A tool that shows where there is waste in a process.
Lower skill requirements - faster - less chance for error.

2. What is a Gage R&R?
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).
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
The ratio of outputs to inputs; 1-scrap.
To obtain a certain desirable outcome from the process

3. DOE
Define - measure - analyze - design - verify.
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
If the Response vs. Levels graph if the response lines are not parallel (crossing)
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

4. What is Type II Error?
Conformance to specifications.
Concluding there has not been an effect/change when there has.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
Supplier - input - process - output - customer.

5. Complete this quality phrase: 'Fix the process - not the _____.'
What the value of the dependent variable is when the independent variable is zero.
Actual drawings - layouts - maps - etc which show where a defect occurs
Blame.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

6. Define takt time.
Variable.
The cycle time required to meet demand.
A diagram that shows the relationships between activities in a project network.
The degree to which a product meets pre-established standards.

7. The Test Statistic (TS)
Lean (or JIT).
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
A random variable that summarizes the information from the sample(s).
68%

8. In a regression - what does R-square tell you?
Stratify a particular defect type according to logical criteria
Kaoru Ishikawa.
Someone who is consistently against virtually everything.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

9. 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.
Taguchi
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

10. 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.
The degree to which a product meets pre-established standards.
50%
Someone who is consistently against virtually everything.

11. Pareto Analysis
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Hold all input variables constant except one. Observe the response as you vary the single input.
The cycle time required to meet demand.

12. What is the difference between the way sampling is done for SPC and for acceptance sampling?
Walter A. Shewhart
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Sampling for SPC is done real time.
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

13. Test for constant variance
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.
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
Lower skill requirements - faster - less chance for error.
The manager in charge of a process being improved in a Six Sigma project.

14. What is a run chart?
A time series plot.
Attribute.
Inventory = throughput x flow time.
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

15. Based on what principal can we use the normal distribution assumptions for SPC?
Central Limit Theorem
The secondary characteristics of a product; "bells and whistles."
5%
Sort - Set in Order - Shine - Standardize - Sustain

16. What are two other names for an Ishikawa diagram?
A diagram that shows the relationships between activities in a project network.
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Is what induces the failure
Fishbone - cause-and-effect diagram.

17. With Six Sigma capability - how many defects per million opportunities would you see?
Attribute.
3.4 (assuming 1.5 sigma shift in the mean)
Represents the behavior of a process
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

18. Creating a Run Chart
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
A time series plot.
Critical to quality.

19. What type of risk is associated with Type II Error?
Pleasing to the senses.
The House of Quality.
Consumer risk.
A tool that shows performance along key dimensions all at once.

20. Detection Criteria Ranking
Fractional factorial designs (orthogonal arrays)
10 if Almost impossible to detect
Workers - machines - materials.
A tool that shows performance along key dimensions all at once.

21. What does SIPOC stand for?
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Supplier - input - process - output - customer.
The number of standard deviations some value is from the mean.
Sort - Set in Order - Shine - Standardize - Sustain

22. Define benchmarking.
Mean time to replacement.
Kaoru Ishikawa.
Studying firms with the best performance in a particular area.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

23. Which type of SPC measurement is more precise - variable or attribute?
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
10 if Almost impossible to detect
Producer risk.
Variable.

24. Define product reliability.
Mean time to failure.
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
A brainstorming tool that shows the connections between ideas.
Producer risk.

25. What is Little's Law?
Prevention and appraisal costs are balanced against internal and external failure.
The gap between what is promised and what is delivered.
X-bar-bar
Inventory = throughput x flow time.

26. What are the 5 Ss?
Different types of defects are listed (used for Pareto chart)
Prevention - appraisal - internal failure - external failure.
Sort - Set in Order - Shine - Standardize - Sustain
Walter A. Shewhart

27. Define aesthetic quality.
To obtain a certain desirable outcome from the process
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
0.9^3 or 72.9%
Pleasing to the senses.

28. ANOVA

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29. One factor at a time (OFAT)
50%
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Observed variation in response is caused by the input
Fishbone - cause-and-effect diagram.

30. What is a Pareto chart?
A tool that shows where there is waste in a process.
Technical quality is the "what" of the service; functional quality is the "how."
Variable.
A descending order-sorted bar chart with a cumulative percentage line.

31. Process check sheets
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Used to create frequency distribution tally sheets
Stratify a particular defect type according to logical criteria
10 for Hazardous without warning 1 for none

32. In a regression - what does the standard error of the estimate tell you?
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
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
Financial - customer - internal process - innovation and learning.

33. DFMEA
Organize ideas into meaningful categories by recognizing their underlying similarity
Walter A. Shewhart
The manager in charge of a process being improved in a Six Sigma project.
Initiated before or at design concept finalization

34. If a three-stage process has 90% yields at each stage - what is the overall yield?
Central Limit Theorem
Attribute.
0.9^3 or 72.9%
Producer risk.

35. Defect check sheets
Initiated before or at design concept finalization
Different types of defects are listed (used for Pareto chart)
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
=sqrt((p*(1-p)/n)

36. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Fractional factorial designs (orthogonal arrays)
QFD
99.73%
The primary operating characteristics of a product.

37. Who is a process owner?
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
Upper control limit.
The manager in charge of a process being improved in a Six Sigma project.
Stratify a particular defect type according to logical criteria

38. Define yield.
Concluding there has been an effect/change when there has not.
The cycle time required to meet demand.
The ratio of outputs to inputs; 1-scrap.
A descending order-sorted bar chart with a cumulative percentage line.

39. What is the formula for standard deviation?
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).
=sqrt(Σ(x-x-bar)^2)/(n-1))
Variable.
Stratify a particular defect type according to logical criteria

40. When is Cpk used?
Lean is waste reduction - Six Sigma is variation reduction.
Different types of defects are listed (used for Pareto chart)
To do a capability study for a non-centered process.
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

41. When yields decrease - what are the two effects on contribution?
No -- only if the process is also capable.
Sampling for SPC is done real time.
A time series plot.
Fewer good units to sell - increased variable cost/unit.

42. What is FMEA?
Actual drawings - layouts - maps - etc which show where a defect occurs
Failure Modes and Effects Analysis
Fitness for use.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

43. 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.
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
QFD
Reliability - Assurance - Responsiveness - Tangibles - Empathy

44. List two components of prevention cost.
Someone who is consistently against virtually everything.
The gap between what is promised and what is delivered.
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.

45. What do you do when a process is out of control?
Look for the assignable cause of non-random variation.
The gap between what is promised and what is delivered.
To mentor/coach (and sometimes train) black belts.
A brainstorming tool that shows the connections between ideas.

46. What is Value Stream Mapping?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Method developed by Ishikawa to graphically display the causes of any given problem
A tool that shows where there is waste in a process.
Controlling quality at the source.

47. What does DMAIC stand for?
Define - measure - analyze - design - verify.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Define - measure - analyze - improve - control.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

48. What is a Gantt chart?
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
A time series plot.
Shifts - Trends - Repeating patterns - Correlation with known events
Shows the temporal flow of activities in a project network.

49. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Supplier - input - process - output - customer.
Prevention and appraisal costs are balanced against internal and external failure.
Define - measure - analyze - design - verify.
Observed variation in response is caused by the input

50. In the Service Quality Gap Model - what is Gap 4?
The target number of standard deviations from the mean for specifications.
The gap between what is promised and what is delivered.
Define - measure - analyze - design - verify.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.