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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. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
The secondary characteristics of a product; "bells and whistles."
Rapid improvement process.
100%
=sqrt(Σ(x-x-bar)^2)/(n-1))

2. To what does the Six in Six Sigma relate?
Consumer risk.
The target number of standard deviations from the mean for specifications.
Shifts - Trends - Repeating patterns - Correlation with known events
Walter A. Shewhart

3. Affinity Diagrams
To do a capability study for a non-centered process.
Mistake-proofing.
Large enough to find two of the attribute - on average.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

4. Uses of regression
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Hold all input variables constant except one. Observe the response as you vary the single input.
Variable.
System to reduce waste and optimize productivity through maintaining an orderly workplace and using visual cues to achieve more consistent operational results.

5. In the Service Quality Gap Model - what is Gap 2?
The gap between what management thinks customers want and the process specifications.
Because the mean and standard deviation are independent of each other.
5%
Hold all input variables constant except one. Observe the response as you vary the single input.

6. Definition of Interaction
Consumer risk.
The cycle time required to meet demand.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Prediction and estimation. based on an unknown x value - estimation is based on a known x value

7. F value
The gap between what is promised and what is delivered.
F_alpha - df(tr) - df (error)
The target number of standard deviations from the mean for specifications.
Attribute

8. In a regression - what does the standard error of the estimate tell you?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
Outside.
A scatterplot.
Represents the behavior of a process

9. What is an affinity diagram?
Workers - machines - materials.
A brainstorming tool that shows the connections between ideas.
Represents the behavior of a process
Controlling quality at the source.

10. What type of risk is associated with Type 1 Error?
The ability of a process to consistently meet customer specifications.
Producer risk.
Shifts - Trends - Repeating patterns - Correlation with known events
Fitness for use.

11. Failure effect
It looks to minimize the probability of a failure - or to minimize its effects
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
Is the consequence of the failure.
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).

12. What is the role of a black belt?
Before production starts
68%
10 for Hazardous without warning 1 for none
To manage the Six Sigma project.

13. Complete this quality phrase: 'Fix the process - not the _____.'
Concluding there has been an effect/change when there has not.
Mistake-proofing.
Blame.
10 for Hazardous without warning 1 for none

14. What is a histogram?
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Upper control limit.
Fractional factorial designs (orthogonal arrays)
95%

15. Who is a process owner?
0.9^3 or 72.9%
The manager in charge of a process being improved in a Six Sigma project.
Before production starts
Is what induces the failure

16. Define conformance quality.
The target number of standard deviations from the mean for specifications.
It's good -- but it's still out of control!
0.9^3 or 72.9%
The degree to which a product meets pre-established standards.

17. Regression
To be a member of a Six Sigma project team.
Producer risk.
The gap between specifications and how service is performed.
Represents the behavior of a process

18. When yields decrease - what are the two effects on contribution?
Rapid improvement process.
Fewer good units to sell - increased variable cost/unit.
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.

19. How are LQL and AQL determined in an acceptance sampling plan?
Through producer/consumer negotiation.
Attribute.
The manager in charge of a process being improved in a Six Sigma project.
Upper control limit.

20. Advantages of DOE
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
Prevention and appraisal costs are balanced against internal and external failure.
Fishbone - cause-and-effect diagram.
QFD

21. Non-random patterns (Run Charts)
Fractional factorial designs (orthogonal arrays)
Shifts - Trends - Repeating patterns - Correlation with known events
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The secondary characteristics of a product; "bells and whistles."

22. Name the structure associated with Quality Function Deployment.
Is the way in which the failure is manifested.
Someone who is consistently against virtually everything.
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
The House of Quality.

23. Define aesthetic quality.
Is the consequence of the failure.
Pleasing to the senses.
Consumer risk.
Studying firms with the best performance in a particular area.

24. Test for Independence
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
Sort - Set in Order - Shine - Standardize - Sustain
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

25. List two components of internal failure.
=sqrt((p*(1-p)/n)
A chart that breaks the range of data into equal intervals and then shows the count of occurrences in each interval.
Define - measure - analyze - improve - control.
Scrap - rework - retest - downtime - yield losses - disposition costs.

26. What are the four categories of costs in Juran's framework?
Used to create frequency distribution tally sheets
Lean (or JIT).
Prevention - appraisal - internal failure - external failure.
Through producer/consumer negotiation.

27. What do you do when a process is out of control?
Critical to quality.
The degree to which a product meets pre-established standards.
Look for the assignable cause of non-random variation.
Is the consequence of the failure.

28. An SPC chart shows no points outside the control limits. Does this mean the process is in control?
Outside.
Taguchi
False - because each machine will have different natural tolerances.
No -- the variation also has to be random and "expected."

29. Regression Analysis
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
Technique used to relate through a model - one or more independent variables and a dependent variable (response)
The gap between what is promised and what is delivered.
Large enough to find two of the attribute - on average.

30. What is the center line of a p-chart?
Fractional factorial designs (orthogonal arrays)
10 if Almost impossible to detect
p-bar - the long-run percent defective.
Failure Modes and Effects Analysis

31. Manual Test for Nomality
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
3.4 (assuming 1.5 sigma shift in the mean)
Deming.
Can't tell without a Range chart.

32. Failure Mode
Pleasing to the senses.
Causes that lead to a particular effect.
Variable.
Is the way in which the failure is manifested.

33. In Juran's Cost of Quality model - which categories of costs balance which other categories?
To monitor a process when measurement by attribute is used.
Prevention and appraisal costs are balanced against internal and external failure.
Shifts - Trends - Repeating patterns - Correlation with known events
Taguchi

34. What is written on the "spines" of a fishbone diagram?
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Causes that lead to a particular effect.
A descending order-sorted bar chart with a cumulative percentage line.
Defects Per Million Opportunities

35. What are the three main categories of assignable cause?
Workers - machines - materials.
A descending order-sorted bar chart with a cumulative percentage line.
Pleasing to the senses.
The US national quality award.

36. Design of Experiments (DOE) approach
Not necessarily.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Concluding there has not been an effect/change when there has.
They move closer to the center line.

37. Histogram by Hand
To monitor a process when measurement by attribute is used.
Fitness for use.
Producer risk.
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

38. What quality tool formally incorporates the voice of the customer?
Speed - courtesy - competence - and ease of repair.
Financial - customer - internal process - innovation and learning.
Define - measure - analyze - design - verify.
QFD

39. Defect check sheets
Different types of defects are listed (used for Pareto chart)
The ability of a process to consistently meet customer specifications.
Conformance to specifications.
= 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

40. What are the Five Dimensions of Service Quality?
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
Variable.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

41. What is DPMO?
Prevention - appraisal - internal failure - external failure.
To be a member of a Six Sigma project team.
100%
Defects Per Million Opportunities

42. What is poka yoke?
0.9^3 or 72.9%
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
Lower skill requirements - faster - less chance for error.
Mistake-proofing.

43. What is a Pareto chart?
The ability of a process to consistently meet customer specifications.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
Linearity - normality - homoscedasticity - independence.
A descending order-sorted bar chart with a cumulative percentage line.

44. What is the formula for the standard deviation of a proportion?
The cycle time required to meet demand.
Fitness for use.
=sqrt((p*(1-p)/n)
No -- if it is not the same - it can only be worse!

45. DFMEA
Fractional factorial designs (orthogonal arrays)
Conformance to specifications.
Lean (or JIT).
Initiated before or at design concept finalization

46. FMEA
= yij - y(bar)i --> value minus sum of that treatment (of row)
Attribute.
It looks to minimize the probability of a failure - or to minimize its effects
A brainstorming tool that shows the connections between ideas.

47. What percentage of a normal distribution lies above the mean?
50%
Lean (or JIT).
Variable.
Deming.

48. 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?
=sqrt((p*(1-p)/n)
False - because each machine will have different natural tolerances.
To do a capability study for a non-centered process.
Observed variation in response is caused by the input

49. Residual(eij)
The gap between what customers expect and the service they receive.
=sqrt(Σ(x-x-bar)^2)/(n-1))
= yij - y(bar)i --> value minus sum of that treatment (of row)
Brand image.

50. DOE
A random variable that summarizes the information from the sample(s).
The cycle time required to meet demand.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan