When a process has proven itself to function at a Six Sigma level this means there are less than ________ defects per million opportunities.
- A . 1.7
- B . 2.6
- C . 3.4
- D . 10
Six Sigma refers to a process whose output has at least 95% of its data points within 6 Standard Deviations from the Mean.
- A . True
- B . False
Training cost is $3,000 and a project required an initial investment of $12,000.
If the project yields monthly savings of $1,800 beginning after 3 months, what is the payback period in months (before money costs and taxes)?
- A . 4.17
- B . 8.33
- C . 11.33
- D . 28.28
The ROI for a project is a measurement metric that stands for Return on Investment and is one of the methods used to measure the success of a Lean Six Sigma project.
- A . True
- B . False
The DMAIC approach to problem solving stands for Define, __________, Analyze, Improve and Control.
- A . Manage
- B . Measure
- C . Memorize
- D . Manipulate
Voice of the Customer is a Lean Six Sigma technique to determine the ___________ attributes of a product or service.
- A . Desirable
- B . Beneficial
- C . Critical-to-Quality
- D . Preferred
Benefits and working conditions would be primarily the concern of which of the following?
- A . Voice of the Customer
- B . Voice of the Employee
- C . Voice of the Business
- D . Voice of the Process
In the expression Y = f(Xn) Y, the output, is the ___________ variable and Xn, the inputs, are the __________ variables.
- A . Independent, dependent
- B . Individual, multiple
- C . Sole, multiple
- D . Dependent, independent
When we assess the Voice of the Customer we are attempting to determine the gaps in our processes between “what is” and __________________.
- A . “What isn’t”
- B . “What will make money”
- C . “What will cost less”
- D . “What should be”
Which of the following would likely not be a CTQ (Critical-to-Quality) for the purchase of a product?
- A . Functionality
- B . Durability
- C . Dependability
- D . None
The Pareto Chart is a tool that displays data that typically follows what ratio?
- A . 70:30
- B . 80:20
- C . 90:10
- D . 95:5
Al bought a handheld GPS from his local electronics store. When he entered an address it would not function.
For the manufacturer of the GPS this would be categorized as what type of cost?
- A . Internal Failure Cost
- B . Prevention Cost
- C . External Failure Cost
- D . Appraisal Cost
Which of the following is a method of expressing the concept that the outputs of a process are a function of all the inputs to the process?
- A . Y = f(Xn)
- B . RTY > 90%
- C . Yield = Effort
- D . Flow = Demand
When we create a Process Map and want to depict an action step in the process we would use the ____________ symbol.
- A . Diamond
- B . Circle
- C . Ellipse
- D . Rectangle
A Belt has determined that the loan application does not need to be reviewed by accounting thereby improving the number of applications a loan processer can handle. According to Cost of Poor Quality (COPQ) definitions RTY improvement would be considered _______________.
- A . Downsizing savings
- B . Hard savings
- C . Soft savings
- D . Median savings
The following Business Case is constructed properly.
“During most of 2008 Division 16 experienced a 4.2% product return rate versus a target of nearly no returns. This costs the company a whole bunch of money.
- A . True
- B . False
The essence of Lean is to concentrate effort on ____________________ while improving process flow to achieve speed and agility at lower cost.
- A . Defect removal
- B . Removing waste
- C . Overtime reduction
- D . Rework reduction
As a Belt created a Process Map he realized there were multiple departments involved in this process so he added a feature to the map called ______________.
- A . Passing Lanes
- B . Swim Lanes
- C . Department Dividers
- D . Responsibility Paths
As we conceive and define a LSS project one of the overriding things we hope to accomplish is to reduce the _____________________.
- A . Work force
- B . Number of process steps
- C . Inventory
- D . Cost of Poor Quality
The Value Chain in an organization is the sum total of all the processes which occur in the business to take inputs and turn them into customer desired outputs.
- A . True
- B . False
A key metric in Six Sigma is the DPMO which stands for __________________?
- A . Delayed production metrics output
- B . Defects by management oversight
- C . Defects per million opportunities
- D . Developed production management oversight
Cycle Time, Defects, Scrap Cost and Safety are examples of business metrics or commonly referred to as which of the following?
- A . Defects per Unit
- B . Key Performance Indicators
- C . Impediments to Flow
- D . Hidden Costs
To construct a Fishbone Diagram and capture all the issues of interest it is best if your team uses the ________________ approach.
- A . Graphical
- B . Data collection
- C . Shewhart
- D . Brainstorming
A 5 Why Analysis is used to help identify possible defect causes when which one of the below listed tools is created?
- A . Fishbone Diagram
- B . SIPOC
- C . X-Y Matrix
- D . Pareto Chart
The purpose of a Process Map is to identify the complexity of the process and to assist in identifying ______________ in the process.
- A . Critical steps
- B . Line operators
- C . Test stations
- D . Defects
At the start of a project we are told to “walk the process” from beginning to the end. We do this to_____________________.
- A . Meet the workers
- B . Draft a Process Map
- C . See what inventory is involved
- D . Check the repair stations
The “Method” category of Root Causes on a Fishbone Diagram is primarily used to generate ideas as to the possible causes for defects by the ____________.
- A . Inventory management
- B . Effects of the environment
- C . Way work is done
- D . Parts or forms used
When we create a Process Map we use a __________ to show the direction of work flow.
- A . Solid line arrow
- B . Dashed line arrow
- C . Series of dots
- D . Double lines
At the beginning of a project we must keep in mind there are basically three views of a process: What you THINK it is, what it ACTUALLY is and What is DOCUMENTED.
- A . True
- B . False
One of the primary deliverables from performing a SIPOC is to begin to understand which inputs have the greatest affect on the ____________ most valued outputs.
- A . Business’s
- B . Employee’s
- C . Management’s
- D . Customer’s
A Macro Process Map may map a process showing the entire activities of a department and can likely be broken into many Micro Process Maps showing numerous processes that comprise the activities of the department.
- A . True
- B . False
SIPOC stands for Suppliers, Inputs, ___________ , Output and Customers.
- A . Production
- B . Process
- C . Products
- D . Presentation
As we begin to describe the things occurring with our process through a Process Map we begin to see some steps that are NVA which stands for ____________.
- A . Non-value add
- B . No violation allowed
- C . Non-value actions
- D . Next vehicle action
As we identify customer and supplier requirements for a SIPOC we are urged to use the RUMBA approach which stands for Reasonable, Understandable, _____________, Believable and Achievable.
- A . Manageable
- B . Massive
- C . Memorable
- D . Measurable
Inputs that may affect your process to some degree but are not critical, are difficult to quantify and are random in nature are referred to as ___________.
- A . Nuisance
- B . Noise
- C . Pests
- D . Elusive
Long-term Data represents all the variation that one can expect to experience from the output of the subject process.
- A . True
- B . False
The temperature of a liquid is being measured by a line operator.
Which is least likely to be influenced by the instrument?
- A . Recording the measurement
- B . Actual temperature of the liquid
- C . Calibration of the instrument
- D . Reading of the instrument
One of the primary benefits of your team working together to create an X-Y Diagram is that the data collected from this exercise is accurate and certain.
- A . True
- B . False
Measurement System Analysis is a procedure used to quantify variation of the method or system used for taking measurements and used to assure usable data is collected.
- A . True
- B . False
A Belt gathered the following defect data for a trouser production line and wanted to assemble it into a Pareto Chart. The correct order from left to right in the chart would be:
Data: Cutting 29
Forming 43
Stitching 17
Sealing 51
- A . Sealing, Forming, Cutting, Stitching
- B . Cutting, Stitching, Sealing, Forming
- C . Stitching, Forming, Cutting, Sealing
- D . Forming, Cutting, Sealing, Stitching
One of the primary objectives of constructing an X-Y Diagram is to separate the vital few X’s from the trivial many X’s.
- A . True
- B . False
Stability, Bias and Linearity define the ___________ of a Measurement System.
- A . Sensitivity
- B . Repeatability
- C . Accuracy
- D . Precision
A tool we use to identify possible failures (defects) in our process and the impact they may have is the _________________.
- A . Shewhart Analysis
- B . Juran Journey
- C . FMEA
- D . SIPOC
The RPN or Risk Priority Number is used to rank the various Failure Modes as to their impact on the output of the subject process.
- A . True
- B . False
The purpose of ________________ is to analyze data and present it in a way we can make informed decisions as to what is happening in our process.
- A . Data Sampling
- B . Basic Statistics
- C . Calculating Standard Deviation
- D . Measurement System Analysis
Process Capability is defined based on customer requirements, defect free performance and output over time.
- A . True
- B . False
Lean Principles defines for us ________ specific areas where waste typically exists in our processes.
- A . Three
- B . Five
- C . Seven
- D . Nine
It is recommended that when beginning a 5S program it be started in a pilot work area for learning and demonstration purposes then it is expended throughout the plant.
- A . True
- B . False
As part of a Visual Factory plan _____________ are created and utilized to identify areas in need of cleaning and organization.
- A . Flashing lights
- B . Soft horns
- C . Kanban cards
- D . Operator announcement programs
One of the 5S approaches to eliminating waste is to minimize work activities that are out of the ordinary thereby requiring unusual decisions and actions to accomplish the correct things. This 5S tool is called __________________.
- A . Standardizing
- B . Scheduling
- C . Sustaining
- D . Sorting
The Control Plan is the road map to sustaining the improvements made through the Lean Six Sigma project and should therefore involve keeping the __________ up to date as a means of supporting the Response Plan.
- A . X-Y Diagram
- B . Shewhart Chart
- C . FMEA
- D . Customer Service Plan
To minimize waste through the application of Lean Principles we do which of the following?
- A . Organize tools and raw materials
- B . Keep the work area clean and organized
- C . Maintain a proper volume of inventory at hand
- D . All of these answers are correct
A Lean Principle that states the process of eliminating waste is a continual process requiring one to always be on the lookout for ways to reduce the seven elements of waste is known as ____________ .
- A . Kaizen
- B . Ishikawa
- C . Kanban
- D . Muda
An important factor in a viable Control Plan is to determine who, when and to what level various personnel must be _________ to maintain the improvements made to a process.
- A . Transferred
- B . Promoted
- C . Trained
- D . Dismissed
Upon completion of a project a Belt must complete the ____________________ then transfer responsibility for this to the Process Owner.
- A . Final Process Map
- B . Project Timesheet
- C . Team Briefing Paper
- D . Documentation Plan
Systems and structures are the basis for allowing people to change their behaviors permanently and are accomplished through which of the following?
- A . Documented performance objectives
- B . Defined procedures
- C . Accurate job descriptions
- D . Incentive compensation
- E . All of these answers are correct
The Control Plan is created following the finalization of the Measure Phase and can be closed when?
- A . After the project costs have been recouped
- B . When the Champion says so
- C . Never, a Control Plan must stay in place
- D . At the fiscal yearend of the business
To reduce the people or operator introduced defects into a process it is best if a Belt can design and implement a means of ________________ into the process.
- A . Measurement automation
- B . Operator alertness
- C . Full Automation
- D . Constant supervision
A Monitoring Plan put into place at the conclusion of a project will provide for adequate systems with key metric readouts indicating out-of-spec conditions.
- A . True
- B . False
When a process has proven itself to function at a Six Sigma level this means there are less than 3.4 defects per ___________ opportunities.
- A . Hundred
- B . Thousand
- C . Million
- D . Billion
Six Sigma refers to a process whose output has 100% of its data points within 8 Standard Deviations from the Mean.
- A . True
- B . False
Training cost $2,500 and a project required an initial investment of $23,500. If the project yields monthly savings of $2,500 beginning after 4 months, what is the payback period in months (before money costs and taxes)?
- A . 7.2
- B . 10.4
- C . 14.4
- D . 28.8
The ROI for a project is a measurement metric that stands for _____________________ and is one of the methods used to measure the success of a Lean Six Sigma project.
- A . Return on Investment
- B . Recognition of Innovation
- C . Recovery of Investment
- D . Return on Inventory
The DMAIC approach to problem solving stands for Define, __________, Analyze, Improve and Control.
- A . Manage
- B . Measure
- C . Memorize
- D . Manipulate
Voice of the Business is a Lean Six Sigma technique to determine the needs and wants of the ______________ of the business.
- A . Owners
- B . Managers
- C . Debt holders
- D . Staff
Y, the output of a process, is the ______________ variable while Xn, the various inputs to a process, are the _____________ variables.
- A . Independent, dependent
- B . Individual, multiple
- C . Sole, multiple
- D . Dependent, independent
Which of the following would likely be a CTQ (Critical-to-Quality) for the purchase of a service?
- A . Documentation is clear
- B . Was timely in delivery
- C . Required no redo
- D . All of these answers are correct
Al bought a digital camera from his local electronics store. When he first used it he found the zoom lens function was inoperative because a gear was installed improperly.
For the manufacturer of the camera this would be categorized as what type of cost?
- A . Internal Failure Cost
- B . Prevention Cost
- C . External Failure Cost
- D . Appraisal Cost
The formula Y = f(Xn) is a method of expressing the concept that the output of a process is a function of all the __________________?
- A . Materials and labor
- B . Inputs to the process
- C . Line personnel and direct supervision
- D . Employees of the company
A Belt has determined that the insurance claim form needn’t be reviewed by accounting thereby improving the number of claims a processer can handle. According to Cost of Poor Quality (COPQ) definitions RTY improvement would be considered _______________.
- A . Downsizing savings
- B . Median savings
- C . Soft savings
- D . Hard savings
The following Business Case is constructed properly. “During 2009 the commercial loan division experienced a 2.7% default rate versus a target of less than .5%. This costs the bank in excess of $250,000 quarterly.”
- A . True
- B . False
As we attempt to find a commonality of terms to assess the performance of a broad range of processes we use a key metric called the DPMO which stands for __________________________?
- A . Delayed production metrics output
- B . Defects by management oversight
- C . Defects per million opportunities
- D . Developed production management oversight
In an organization is the sum total of all the processes which occur in the business to take inputs and turn them into customer desired outputs is called the Value Chain.
- A . True
- B . False
When a Belt wishes to clarify the activities of various departments in a Process Map she is creating she adds a feature to the map called ______________.
- A . Department Dividers
- B . Passing Lanes
- C . Swim Lanes
- D . Responsibility Paths
With a Fishbone Diagram we use the legs to define each source of a potential defect and along the legs we enter each potential means by which a defect could be introduced into our process.
- A . True
- B . False
The purpose of a ______________ is to identify the complexity of the process and to assist in identifying critical steps in the process.
- A . Pareto Chart
- B . Process Map
- C . Kanban
- D . Kaizen event
In order to properly draft a Process Map at the start of a project we are told to __________________ from beginning to the end.
- A . Interview the line operators
- B . Walk the process
- C . Chat with supervisors
- D . Check the repair stations
The “Equipment” category of Root Causes on a Fishbone Diagram would be used primarily used to generate ideas as to which of the following are possible causes for defects?
- A . Out of calibration measurement system
- B . Tolerance changes in milling machines
- C . Worn bearings on a shaft
- D . All of these answers are correct
At the beginning of a project we must keep in mind there are basically three views of a process: What you THINK it is, What the SUPPLIER wants and What it SHOULD be.
- A . True
- B . False
A Micro Process Map may map a process showing the entire activities of a department and can likely be broken into many Macro Process Maps showing numerous processes that comprise the activities of the department.
- A . True
- B . False