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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. Who is a process owner?
The manager in charge of a process being improved in a Six Sigma project.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed
Observed variation in response is caused by the input

2. Define features.
Used to create frequency distribution tally sheets
To be a member of a Six Sigma project team.
The secondary characteristics of a product; "bells and whistles."
Taguchi

3. List two components of internal failure.
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
A random variable that summarizes the information from the sample(s).
Scrap - rework - retest - downtime - yield losses - disposition costs.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"

4. Based on what principal can we use the normal distribution assumptions for SPC?
To monitor a process when measurement by attribute is used.
Central Limit Theorem
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
The ability of a process to consistently meet customer specifications.

5. In the Service Quality Gap Model - what is Gap 4?
The gap between what is promised and what is delivered.
Is the way in which the failure is manifested.
Different types of defects are listed (used for Pareto chart)
Concluding there has been an effect/change when there has not.

6. What quality tool formally incorporates the voice of the customer?
Lower control limit.
10 for Hazardous without warning 1 for none
QFD
A random variable that summarizes the information from the sample(s).

7. What are the three main categories of assignable cause?
Workers - machines - materials.
A tool that shows performance along key dimensions all at once.
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables
A tool that shows the physical flows through a space.

8. Stratified defect check sheets
A tool that shows performance along key dimensions all at once.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Lower skill requirements - faster - less chance for error.
Stratify a particular defect type according to logical criteria

9. When yields decrease - what are the two effects on contribution?
Lower skill requirements - faster - less chance for error.
Fewer good units to sell - increased variable cost/unit.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.
The House of Quality.

10. What is the center line of an X-bar chart?
X-bar-bar
10 for Hazardous without warning 1 for none
Producer risk.
Because the mean and standard deviation are independent of each other.

11. Define aesthetic quality.
3.4 (assuming 1.5 sigma shift in the mean)
Outside.
Pleasing to the senses.
Lower skill requirements - faster - less chance for error.

12. Residual
0.9^3 or 72.9%
A diagram that shows the relationships between activities in a project network.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
A time series plot.

13. With Six Sigma capability - how many defects per million opportunities would you see?
3.4 (assuming 1.5 sigma shift in the mean)
Pleasing to the senses.
Attribute.
Studying firms with the best performance in a particular area.

14. Which type of SPC measurement is more precise - variable or attribute?
The gap between what is promised and what is delivered.
Variable.
Observed variation in response is caused by the input
Consumer risk.

15. Histogram by Hand
5%
Concluding there has been an effect/change when there has not.
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
Lower skill requirements - faster - less chance for error.

16. One factor at a time (OFAT)
A tool that shows the physical flows through a space.
To do a capability study for a non-centered process.
Deming.
Hold all input variables constant except one. Observe the response as you vary the single input.

17. What is the center line of a p-chart?
Kaoru Ishikawa.
The gap between specifications and how service is performed.
Initiated before or at design concept finalization
p-bar - the long-run percent defective.

18. What is the role of a green belt?
To be a member of a Six Sigma project team.
Conformance to specifications.
The process of ranking opportunities to determine which of many potential opportunities should be pursued first.
A tool that shows the physical flows through a space.

19. What is a CAVE man?
Someone who is consistently against virtually everything.
If the Response vs. Levels graph if the response lines are not parallel (crossing)
Lean is waste reduction - Six Sigma is variation reduction.
Hold all input variables constant except one. Observe the response as you vary the single input.

20. What are the four perspectives of the Balanced Scorecard?
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
Supplier - input - process - output - customer.
Financial - customer - internal process - innovation and learning.
The US national quality award.

21. If a three-stage process has 90% yields at each stage - what is the overall yield?
0.9^3 or 72.9%
50%
The gap between what management thinks customers want and the process specifications.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

22. What is a spaghetti diagram?
Conformance to specifications.
100%
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
A tool that shows the physical flows through a space.

23. What are the Five Dimensions of Service Quality?
Central Limit Theorem
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
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
Reliability - Assurance - Responsiveness - Tangibles - Empathy

24. Defect location check sheets
The gap between what management thinks customers want and what customers really want.
Represent the errors which are random variables with an assumed normal distribution with mean zero and a constant variance σ2.
Actual drawings - layouts - maps - etc which show where a defect occurs
Hold all input variables constant except one. Observe the response as you vary the single input.

25. What is Kaizen?
They move closer to the center line.
The primary operating characteristics of a product.
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
Rapid improvement process.

26. PFMEA
Lower control limit.
The House of Quality.
Before production starts
10 if Almost impossible to detect

27. Definition of Interaction
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces
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).
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Define - measure - analyze - improve - control.

28. Why do you need two control charts for variables SPC?
68%
Concluding there has been an effect/change when there has not.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
Because the mean and standard deviation are independent of each other.

29. In a regression - what does the coefficient of the intercept tell you
X-bar-bar
To do a capability study for a non-centered process.
What the value of the dependent variable is when the independent variable is zero.
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

30. Detection Criteria Ranking
10 if Almost impossible to detect
Taguchi
A diagram that shows the relationships between activities in a project network.
Prevention - appraisal - internal failure - external failure.

31. What is the role of a black belt?
Concluding there has been an effect/change when there has not.
To manage the Six Sigma project.
5%
The House of Quality.

32. What is the difference between the way sampling is done for SPC and for acceptance sampling?
A tool that shows the physical flows through a space.
Sampling for SPC is done real time.
The gap between what customers expect and the service they receive.
To monitor a process when measurement by variables is used.

33. What graphical tool is used to show the relationship between two numerical variables?
QFD
Workers - machines - materials.
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
A scatterplot.

34. List Garvin's eight dimensions of product quality.
10 for Hazardous without warning 1 for none
Look to your customer - not to other firms. "You can always find someone shorter - fatter and balder!"
Fishbone - cause-and-effect diagram.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

35. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
Failure Modes and Effects Analysis
Mean time to replacement.
100%
Actual drawings - layouts - maps - etc which show where a defect occurs

36. What does SIPOC stand for?
Shifts - Trends - Repeating patterns - Correlation with known events
Concluding there has been an effect/change when there has not.
Supplier - input - process - output - customer.
A brainstorming tool that shows the connections between ideas.

37. What is a run chart?
A time series plot.
The primary operating characteristics of a product.
To obtain a certain desirable outcome from the process
Actual drawings - layouts - maps - etc which show where a defect occurs

38. What is FMEA?
A diagram that shows the relationships between activities in a project network.
The degree to which a product meets pre-established standards.
Failure Modes and Effects Analysis
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

39. Failure Mode
Is the way in which the failure is manifested.
The gap between specifications and how service is performed.
Because the mean and standard deviation are independent of each other.
Causes that lead to a particular effect.

40. DOE
Method developed by Ishikawa to graphically display the causes of any given problem
Controlling quality at the source.
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
A simple graph between two variables - visualize the type - degree of strength and shape of the relationship between two variables

41. List two components of external failure.
The cycle time required to meet demand.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
The gap between what customers expect and the service they receive.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

42. List two components of prevention cost.
To do a capability study for a non-centered process.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
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.

43. What is Value Stream Mapping?
Someone who is consistently against virtually everything.
100%
Producer risk.
A tool that shows where there is waste in a process.

44. Affinity Diagrams
Attribute
X-bar-bar
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions
Hold all input variables constant except one. Observe the response as you vary the single input.

45. For what is a p-chart used?
To monitor a process when measurement by attribute is used.
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
Brand image.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

46. In a regression - what does the p value of F tell you?
Attribute
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 Japanese national quality award.
Incoming materials inspection - inspection and testing - maintaining test equipment - materials/services consumed

47. FMEA
Assigns scores to weighted criteria for each project under consideration.
Financial - customer - internal process - innovation and learning.
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
It looks to minimize the probability of a failure - or to minimize its effects

48. How are LQL and AQL determined in an acceptance sampling plan?
Through producer/consumer negotiation.
A tool that shows where there is waste in a process.
Because the mean and standard deviation are independent of each other.
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

49. Uses of regression - Control
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
To obtain a certain desirable outcome from the process
50%
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).

50. F value
Concluding there has not been an effect/change when there has.
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
F_alpha - df(tr) - df (error)
Actual drawings - layouts - maps - etc which show where a defect occurs