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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. What is a network diagram?
A diagram that shows the relationships between activities in a project network.
An assertion or conjecture concerning one or more populations
Prevention and appraisal costs are balanced against internal and external failure.
To monitor a process when measurement by attribute is used.

2. Does it ever make sense to accept a job when a process is incapable?
Yes - when there are opportunities to improve - when contribution margin is adequate - when achieving market share is important.
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
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).
Scrap - rework - retest - downtime - yield losses - disposition costs.

3. Which type of SPC measurement is more precise - variable or attribute?
Variable.
Failure Modes and Effects Analysis
Consumer risk.
Observed variation in response is caused by the input

4. What is Type 1 Error?
Hold all input variables constant except one. Observe the response as you vary the single input.
Is the way in which the failure is manifested.
Speed - courtesy - competence - and ease of repair.
Concluding there has been an effect/change when there has not.

5. What does DMAIC stand for?
Define - measure - analyze - improve - control.
Sampling for SPC is done real time.
A descending order-sorted bar chart with a cumulative percentage line.
10 for Hazardous without warning 1 for none

6. In a Z table - what is Z?
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
Causes that lead to a particular effect.
Studying firms with the best performance in a particular area.
The number of standard deviations some value is from the mean.

7. FMEA
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
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
Pleasing to the senses.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

8. What percentage of a normal distribution lies above the mean?
A scatterplot.
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality
50%
Data reduction to put a large number of qualitative inputs into a smaller number of major dimensions

9. What is Kaizen?
50%
Concluding there has not been an effect/change when there has.
Prediction and estimation. based on an unknown x value - estimation is based on a known x value
Rapid improvement process.

10. What quality guru emphasizes management as a system?
The number of standard deviations some value is from the mean.
Supplier - input - process - output - customer.
The degree to which a product meets pre-established standards.
Deming.

11. List two components of internal failure.
Scrap - rework - retest - downtime - yield losses - disposition costs.
Upper control limit.
Central Limit Theorem
No -- if it is not the same - it can only be worse!

12. Stratified defect check sheets
The gap between what customers expect and the service they receive.
Stratify a particular defect type according to logical criteria
A tool that shows the physical flows through a space.
Is what induces the failure

13. What is DPMO?
Someone who is consistently against virtually everything.
Defects Per Million Opportunities
5%
Upper control limit.

14. DOE
An experiment where one or more variables believed to have an effect on an experimental outcome are identified and manipulated according to a plan
The US national quality award.
To monitor a process when measurement by attribute is used.
Inventory = throughput x flow time.

15. 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?
False - because each machine will have different natural tolerances.
Producer risk.
Defects Per Million Opportunities
A brainstorming tool that shows the connections between ideas.

16. What is the role of a green belt?
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
=sqrt((p*(1-p)/n)
The amount of variation in the dependent variable that is explained by the variation in the independent variable(s).
To be a member of a Six Sigma project team.

17. What is the role of a black belt?
To manage the Six Sigma project.
Central Limit Theorem
1) Obtain Residuals 2) Fill out table --> y coordinates: F = 100 (i-.5)/N x coordinates: Ordered Residual 3) Plot on Normal Probability Paper
1) Plot a Line chart of the data in time sequence 2) Draw a line at the median

18. What is written on the "spines" of a fishbone diagram?
Look for the assignable cause of non-random variation.
Causes that lead to a particular effect.
=sqrt(Σ(x-x-bar)^2)/(n-1))
Lower skill requirements - faster - less chance for error.

19. What is the Baldrige Award?
X-bar-bar
Blame.
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
The US national quality award.

20. List Garvin's eight dimensions of product quality.
Organize ideas into meaningful categories by recognizing their underlying similarity
To be a member of a Six Sigma project team.
3.4 (assuming 1.5 sigma shift in the mean)
Performance - features - conformance - reliability - durability - serviceability - aesthetics - perceived quality

21. What is the role of a master black belt?
Prevention - appraisal - internal failure - external failure.
Can't tell without a Range chart.
The Japanese national quality award.
To mentor/coach (and sometimes train) black belts.

22. ANOVA

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23. What is a spaghetti diagram?
A tool that shows the physical flows through a space.
Define - measure - analyze - improve - control.
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.

24. Who is a process owner?
Fitness for use.
The manager in charge of a process being improved in a Six Sigma project.
The gap between what management thinks customers want and the process specifications.
Lower control limit.

25. What are the three main categories of assignable cause?
Workers - machines - materials.
Sampling for SPC is done real time.
Define - measure - analyze - design - verify.
Attribute

26. What does SIPOC stand for?
Supplier - input - process - output - customer.
Prevention - appraisal - internal failure - external failure.
Because the mean and standard deviation are independent of each other.
Rank of 10 if there is >= 100 per 1000 piece Rank of 1 if there is <=.01 per 1000 pieces

27. Disadvantages of DOE

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28. In your major - courses are pass-fail. Would you monitor performance using attribute or variable SPC?
= yij - y(bar)i --> value minus sum of that treatment (of row)
Is the consequence of the failure.
An interaction is defined as a dependence relationship between the response and the levels of two or more variables
Attribute

29. Test for Independence
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
They move closer to the center line.
Concluding there has been an effect/change when there has not.
Critical to quality.

30. Design of Experiments (DOE) approach
= yij - y(bar)i --> value minus sum of that treatment (of row)
Vary two or more variables simultaneously - Multiple measurements are obtained under the same experimental conditions
An assertion or conjecture concerning one or more populations
10 if Almost impossible to detect

31. Histogram by Hand
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
Linearity - normality - homoscedasticity - independence.
To do a capability study for a non-centered process.
Defects Per Million Opportunities

32. What type of risk is associated with Type II Error?
Consumer risk.
Concluding there has not been an effect/change when there has.
No; if the process is centered - Cp will be the same; if not - Cpk is what you need to determine capabilty.
Can't tell without a Range chart.

33. When is Cpk used?
Taguchi
Prevention - appraisal - internal failure - external failure.
To do a capability study for a non-centered process.
= 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

34. Define perceived quality (Garvin's framework).
Represents the behavior of a process
Brand image.
Critical to quality.
Taguchi

35. What is the difference between Lean and Six Sigma?
= S x O x D S--> Severity O--> Occurrence D--> Detection Higher the number the worse it is
Lean is waste reduction - Six Sigma is variation reduction.
A tool that shows where there is waste in a process.
=sqrt((p*(1-p)/n)

36. In the Service Quality Gap Model - what is Gap 4?
The secondary characteristics of a product; "bells and whistles."
Is the way in which the failure is manifested.
The gap between what is promised and what is delivered.
Represents the behavior of a process

37. What is the formula for standard deviation?
=sqrt(Σ(x-x-bar)^2)/(n-1))
A time series plot.
Concluding there has been an effect/change when there has not.
Controlling quality at the source.

38. When yields decrease - what are the two effects on contribution?
Kaoru Ishikawa.
= yij - y(bar)i --> value minus sum of that treatment (of row)
Walter A. Shewhart
Fewer good units to sell - increased variable cost/unit.

39. If your process is capable at two sigma - what percentage of the output will you have to inspect to find defectives?
The gap between what customers expect and the service they receive.
Deming.
100%
To manage the Six Sigma project.

40. What is a run chart?
Technical quality is the "what" of the service; functional quality is the "how."
Shows the temporal flow of activities in a project network.
A time series plot.
To monitor a process when measurement by attribute is used.

41. What do you do when a process is out of control?
The secondary characteristics of a product; "bells and whistles."
Look for the assignable cause of non-random variation.
Is the way in which the failure is manifested.
Reliability - Assurance - Responsiveness - Tangibles - Empathy

42. DFMEA
To be a member of a Six Sigma project team.
Fitness for use.
Technical quality is the "what" of the service; functional quality is the "how."
Initiated before or at design concept finalization

43. What is a dashboard?
A tool that shows performance along key dimensions all at once.
Method developed by Ishikawa to graphically display the causes of any given problem
To mentor/coach (and sometimes train) black belts.
A time series plot.

44. Effect ranking (Severity of the Defect)
The target number of standard deviations from the mean for specifications.
10 for Hazardous without warning 1 for none
95%
Assigns scores to weighted criteria for each project under consideration.

45. One factor at a time (OFAT)
Hold all input variables constant except one. Observe the response as you vary the single input.
Technical quality is the "what" of the service; functional quality is the "how."
Sampling for SPC is done real time.
A scatterplot.

46. Non-random patterns (Run Charts)
68%
Shifts - Trends - Repeating patterns - Correlation with known events
Is the consequence of the failure.
Inventory = throughput x flow time.

47. What is an affinity diagram?
How much variance you expect around the prediction; two SEs gives you a 95% confidence interval.
A brainstorming tool that shows the connections between ideas.
Pleasing to the senses.
To monitor a process when measurement by variables is used.

48. Define product reliability.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
Mean time to failure.
Organize ideas into meaningful categories by recognizing their underlying similarity
Lower control limit.

49. List two components of external failure.
To mentor/coach (and sometimes train) black belts.
Quality planning - design review - education and training - process control - IS costs - quality reporting - improvement project costs - working with suppliers before production.
QFD
Complaint adjustment - returned material - warranty charges - allowances - loss of future business.

50. What is the center line of a p-chart?
Concluding there has been an effect/change when there has not.
p-bar - the long-run percent defective.
It looks to minimize the probability of a failure - or to minimize its effects
Fractional factorial designs (orthogonal arrays)