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Six Sigma

Subjects : certifications, six-sigma, business-skills

Instructions:

Answer 50 questions in 15 minutes.
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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 features.
The secondary characteristics of a product; "bells and whistles."
Controlling quality at the source.
To monitor a process when measurement by attribute is 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).

2. In a Z table - what is Z?
Rapid improvement process.
Before production starts
The number of standard deviations some value is from the mean.
A brainstorming tool that shows the connections between ideas.

3. Failure cause
Central Limit Theorem
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
Is what induces the failure
Sampling for SPC is done real time.

4. What graphical tool is used to show the relationship between two numerical variables?
A descending order-sorted bar chart with a cumulative percentage line.
A scatterplot.
Technical quality is the "what" of the service; functional quality is the "how."
Blame.

5. If a three-stage process has 90% yields at each stage - what is the overall yield?
Actual drawings - layouts - maps - etc which show where a defect occurs
0.9^3 or 72.9%
Organize ideas into meaningful categories by recognizing their underlying similarity
Shifts - Trends - Repeating patterns - Correlation with known events

6. When is Cpk used?
Prevention - appraisal - internal failure - external failure.
A tool that shows performance along key dimensions all at once.
To do a capability study for a non-centered process.
Lower control limit.

7. List Garvin's eight dimensions of product quality.
68%
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Supplier - input - process - output - customer.
The secondary characteristics of a product; "bells and whistles."

8. What is an affinity diagram?
Represents the behavior of a process
A brainstorming tool that shows the connections between ideas.
Mean time to replacement.
Is what induces the failure

9. Histogram by Hand
Workers - machines - materials.
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
Outside.
To manage the Six Sigma project.

10. What are two other names for an Ishikawa diagram?
The primary operating characteristics of a product.
3.4 (assuming 1.5 sigma shift in the mean)
Fishbone - cause-and-effect diagram.
No -- the variation also has to be random and "expected."

11. Approximately what percent of a normal distribution falls between ± 1 standard deviations from the mean?
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
No -- the variation also has to be random and "expected."
68%
Actual drawings - layouts - maps - etc which show where a defect occurs

12. Complete this quality phrase: 'Fix the process - not the _____.'
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Blame.
Deming.
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

13. Design of Experiments (DOE) approach
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
A tool that shows where there is waste in a process.
Central Limit Theorem
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions

14. List two components of prevention cost.
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).
The gap between what is promised and what is delivered.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
To be a member of a Six Sigma project team.

15. Define durability.
Upper control limit.
Critical to quality.
Organize ideas into meaningful categories by recognizing their underlying similarity
Mean time to replacement.

16. Name the structure associated with Quality Function Deployment.
The House of Quality.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
F_alpha - df(tr) - df (error)
Different types of defects are listed (used for Pareto chart)

17. Residual
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
It looks to minimize the probability of a failure - or to minimize its effects
Stratify a particular defect type according to logical criteria
Is the consequence of the failure.

18. Failure effect
Hold all input variables constant except one. Observe the response as you vary the single input.
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median
Assigns scores to weighted criteria for each project under consideration.
Is the consequence of the failure.

19. Affinity Diagrams
Stratify a particular defect type according to logical criteria
Walter A. Shewhart
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan

20. When Crosby said - "Quality is free -" what dimension of quality was he referring to?
Conformance to specifications.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Outside.
68%

21. Define perceived quality (Garvin's framework).
Brand image.
Shows the temporal flow of activities in a project network.
The gap between what management thinks customers want and the process specifications.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

22. Approximately what percent of a normal distribution falls between ± 3 standard deviations from the mean?
Stratify a particular defect type according to logical criteria
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
99.73%
Blame.

23. In a regression - what does the p value of F tell you?
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).
Someone who is consistently against virtually everything.
Supplier - input - process - output - customer.
Controlling quality at the source.

24. What is Jidoka?
Controlling quality at the source.
=sqrt((p*(1-p)/n)
Is what induces the failure
Different types of defects are listed (used for Pareto chart)

25. Defect location check sheets
X-bar-bar
Actual drawings - layouts - maps - etc which show where a defect occurs
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
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

26. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
The degree to which a product meets pre-established standards.
No -- the variation also has to be random and "expected."
Is the way in which the failure is manifested.
Can't tell without a Range chart.

27. DFMEA
Sampling for SPC is done real time.
Deming.
The gap between what customers expect and the service they receive.
Initiated before or at design concept finalization

28. Regression
Kaoru Ishikawa.
The gap between what management thinks customers want and the process specifications.
The ratio of outputs to inputs; 1-scrap.
Represents the behavior of a process

29. In Juran's Cost of Quality model - which categories of costs balance which other categories?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
The gap between what customers expect and the service they receive.
Not necessarily.
Prevention and appraisal costs are balanced against internal and external failure.

30. Daniel Test
A random variable that summarizes the information from the sample(s).
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
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:
Stratify a particular defect type according to logical criteria

31. For what is a p-chart used?
The US national quality award.
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 attribute is used.
If the Response vs. Levels graph if the response lines are not parallel (crossing)

32. Who first studied randomness in industrial processes
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).
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
5%
Walter A. Shewhart

33. What is the role of a master black belt?
Concluding there has not been an effect/change when there has.
=sqrt((p*(1-p)/n)
Is the consequence of the failure.
To mentor/coach (and sometimes train) black belts.

34. What is Kaizen?
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
5%
Rapid improvement process.
Can't tell without a Range chart.

35. One factor at a time (OFAT)
The number of standard deviations some value is from the mean.
Observed variation in response is caused by the input
Linearity - normality - homoscedasticity - independence.
Workers - machines - materials.

36. Define serviceability.
Speed - courtesy - competence - and ease of repair.
Because the mean and standard deviation are independent of each other.
5%
Technique used to relate through a model - one or more independent variables and a dependent variable (response)

37. Taguchi's experimental designs are of this type.
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Fractional factorial designs (orthogonal arrays)
The Japanese national quality award.
Mistake-proofing.

38. Why do you need two control charts for variables SPC?
The gap between what management thinks customers want and what customers really want.
Producer risk.
Because the mean and standard deviation are independent of each other.
The manager in charge of a process being improved in a Six Sigma project.

39. For what is an x-bar chart used?
To manage the Six Sigma project.
To monitor a process when measurement by variables is used.
Reliability - Assurance - Responsiveness - Tangibles - Empathy
The gap between specifications and how service is performed.

40. Approximately what percent of a normal distribution falls between ± 2 standard deviations from the mean?
95%
Attribute
Causes that lead to a particular effect.
The ratio of outputs to inputs; 1-scrap.

41. If your process is capable at two sigma - what percentage of the output will be defective (assuming the process is in control)?
5%
Financial - customer - internal process - innovation and learning.
A brainstorming tool that shows the connections between ideas.
The ability of a process to consistently meet customer specifications.

42. What does the abbreviation LCL stand for?
Shows the temporal flow of activities in a project network.
Different types of defects are listed (used for Pareto chart)
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Lower control limit.

43. What is FMEA?
3.4 (assuming 1.5 sigma shift in the mean)
Waste.
Failure Modes and Effects Analysis
To monitor a process when measurement by variables is used.

44. What are the four perspectives of the Balanced Scorecard?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The US national quality award.
To be a member of a Six Sigma project team.
Financial - customer - internal process - innovation and learning.

45. 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).
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Lean is waste reduction - Six Sigma is variation reduction.
The US national quality award.

46. A process is operating "in control." Does this mean the customer's requirements are met?
95%
No -- only if the process is also capable.
Is the way in which the failure is manifested.
Can't tell without a Range chart.

47. What does SIPOC stand for?
What the value of the dependent variable is when the independent variable is zero.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Variable.
Supplier - input - process - output - customer.

48. Which type of SPC measurement is more precise - variable or attribute?
Through producer/consumer negotiation.
=sqrt((p*(1-p)/n)
Variable.
The Japanese national quality award.

49. In the Service Quality Gap Model - what is Gap 5?
No -- if it is not the same - it can only be worse!
Speed - courtesy - competence - and ease of repair.
The gap between what customers expect and the service they receive.
Through producer/consumer negotiation.

50. Define aesthetic quality.
Pleasing to the senses.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Lean is waste reduction - Six Sigma is variation reduction.
Different types of defects are listed (used for Pareto chart)

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Six Sigma

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