Exam 1
The three types of measurement system analysis we studied were: "Audits, Attribute Studies, Gage Studies." "Audits, Attribute Studies, Inspections" "R&R Assessments, Attribute Studies, Gage Studies." "Audits, Inspections, Gage Studies"
"Audits, Attribute Studies, Gage Studies."
Operational definitions: "Define each metric, what the characteristic is, and how to measure it." The statements in an operating manual. Describe the steps required to operate a machine. Describe how to interpret a box-and-whiskers chart.
"Define each metric, what the characteristic is, and how to measure it."
Which of the following statements describes discrete data? The flight arrived at 9:08 PM. "There were 5,923 gallons of fuel consumed on the flight." "Of the 225 people on the airplane, 85 had connecting flights." It takes 3 hours and 48 minutes to fly form LA to New York
"Of the 225 people on the airplane, 85 had connecting flights."
The five project variables are:
"Scope, Schedule, Resources, Cost, Quality"
What is the correct interpretation of short-term process capability ratio value of 1.5? "The process is capable, but it is not a six sigma process." "The process is capable, and it is a six sigma process." The process is not capable. The process is centered.
"The process is capable, but it is not a six sigma process."
The eight forms of waste are
"Transportation, Inventory, Motion, Waiting, Over Processing, Over Production, Defects, Skill"
Which of the following four graphical techniques could easily be used to display the same data? (i) stem-and-leaf plot (ii) box plot (iii) scatter diagrams (iv) Histograms "i, ii, iii only." "i, iii, iv only," "i, ii, iv only." "ii, iii, iv only"
"i, ii, iv only."
Six Sigma
- A method that provides organizations tools to improve the capability of their business processes. This increase in performance and decrease in process variation lead to defect reduction and improvement in profits, employee morale, and quality of products or services. - Six Sigma quality is a term generally used to indicate that a process is well controlled (±6s from the centerline in a control chart).
Considering the Precision Delivery Incorporated (PDI) case, which of the following are an examples of the Voice of the Process (VOP)? (2 correct) - Return on Sales (ROS) must be 30% to grow the business. - Hit the 15-minute pickup/delivery window. - Return on Sales (ROS) must be 20% to remain in business. - Rebates last month were $9,400. - Idle time costs last month were 6.1% of Sales.
- Rebates last month were $9,400. - Idle time costs last month were 6.1% of Sales.
Why do organizations use Six Sigma?
-Creates an organizational network of activities that support the efforts to continually improve on all aspects of the organization -Demonstrates the impact of continual improvement and variation reduction on the organization's bottom line
Using six sigma methodology, a company at 6.0 would have a failure rate of:
3.4 DPMO
The SIPOC diagram stands for Supplier, Input, Process, Output, Customer. It provides a view of the process and should contain approximately how many steps? 4-7 steps. 8-15 steps. 16-20 steps. 21-40 steps.
4-7 steps.
Lean Tools for Control
5S, Visual Factory, Kaizen, Kanban, Poka-Yoke, Total Productive Maintenance, Standard Work, Pull Systems
See Q2_Question One Image - It is a Quality Function Deployment (QFD) House of Quality for a Smart Phone: What is the weighted importance score for the Battery process capability? Please enter your numeric answer below as a whole number.
75
See Q2_Question Four Which of the CTQ Measures (i.e. the right most items) are Discrete (Attribute) data? (2 correct) Not Acidic < 3.00/cup >60c Rich
< 3.00/cup >60c
A scatter diagram is used to plot gas mileage versus the weight of the car. One would expect the shape of the resulting plot to be: Tip, gas mileage is the dependent variable and weight of the car is the independent variable. A low positive. A decreasing slope. No correlation displayed. An increasing slope.
A decreasing slope.
What is a defect?
A measurable characteristic not confirming to a customer requirement
The term "variable" can be described in the following way: A quantity which can assume several (more that two) values. A quantity which can be absent or present in a product. A quantity which is absent in a product in one or more specifications. A definable attributed or characteristic of a product.
A quantity which can assume several (more that two) values.
The term "variable" can be described in the following way: A quantity which can be absent or present in a product. A quantity which is absent in a product in one or more specifications. A quantity which can assume several (more that two) values. A definable attributed or characteristic of a product.
A quantity which can assume several (more that two) values.
The term "variable" can be described in the following way: A quantity which is absent in a product in one or more specifications. A definable attributed or characteristic of a product. A quantity which can assume several (more that two) values. A quantity which can be absent or present in a product.
A quantity which can assume several (more that two) values.
The purpose of the Define phase in the DMAIC methodology is to: To defibe the project and goals. To identify the CTQs. All of the above. To describe and quantify the defect and expected improvement.
All of the above
What is six sigma? Problem solving All the above Culture change Knowledge generation
All of the above
Using a Six Sigma methodology, a company at sigma level of 6.0 would have a failure rate of: A. 233 DPU B. 3.4 DPMO C. 6 DPMO D. 3.4 DPU E. None of the above
B. 3.4 DPMO
Which of the following roles is most likely to lead and manage a Six Sigma project. Green Belt Champion Black Belt Executive Sponsor
Black Belt
Identify the two errors in the swim-lane flowchart seen in Exam 1 _ Question 5. (2 correct) A. The "Unload Truck" activity has an incorrect symbol B. The "Inspect Raw Material" activity has an incorrect symbol C. There is no "Start" symbol D. The "No" branch is missing from the "Pass Inspection" decision
C. There is no "Start" symbol D. The "No" branch is missing from the "Pass Inspection" decision
In the transfer function, f(X) + ɛ = Y, which letter represents the common cause variation? A. f B. X C. ɛ D. Y E. None of the above
C. ɛ
Common Causes
Causes of variation that are inherent in a process over time. They affect every outcome of the process and everyone working in the process. AKA "chance causes"
What is the correct response to a process that is in statistical control but is not meeting specifications? Investigate why the process is out of control. Change the process or specification. Do nothing. Stop the process.
Change the process or specification.
What is the correct response to a process that is in statistical control but is not meeting specifications? Investigate why the process is out of control. Stop the process. Change the process or specification. Do nothing.
Change the process or specification.
The duties of the Six Sigma Executive Sponsor include all of the following EXCEPT: Allocate resources. Coach Six Sigma Green Belts. Initiative incentives and rewards. Establish the vision and set the direction.
Coach Six Sigma Green Belts.
The duties of the Six Sigma Executive Sponsor include all of the following EXCEPT: Establish the vision and set the direction. Coach Six Sigma Green Belts. Initiative incentives and rewards. Allocate resources.
Coach Six Sigma Green Belts.
Which of the following is NOT a work package in the Measure phase? Assess Process Capability Collect the Voice of the Customer Prepare a Data Collection Plan Create an AS IS Value Stream Map
Collect the Voice of the Customer
Which of the following is NOT a work package in the Measure phase? Assess Process Capability Create an AS IS Value Stream Map Prepare a Data Collection Plan Collect the Voice of the Customer
Collect the Voice of the Customer
Which of the following are examples of lag (reactive) Voice of the Customer (VOC) collection techniques? (2 correct) Complaints Interviews Returns Point of Use Observations
Complaints Returns
Which of the following Six Sigma tools breakdown high level customer needs into specific and measurable requirements? Pareto Analysis Affinity Diagrams Critical to Quality Tree Kano Analysis
Critical to Quality Tree
An organized and disciplined approach to problem solving in most six sigma organizations is called:
DMAIC
The goal of the Define Phase can best be described as: "Define the project, the goals, and the transfer function f(x) = y. - "Describe and quantify both the defect and the expected improvement." - "Define the project, the goals, and the deliverables to the internal and external customers. Describe and quantify both the defect and the expected improvement." - "Define the project, the goals, and the deliverables to the external customers. Describe and quantify both the defect and the expected improvement." - "Define the project, the goals, and the deliverables to the internal and external customers. Describe and quantify the expected improvement."
Define the project, the goals, and the deliverables to the internal and external customers. Describe and quantify both the defect and the expected improvement.
Which of the following is NOT a tool for process modeling? SIPOC Diagram FMEA Cross-Functional Flowchart Value Stream Map
FMEA
"The three flows of communication are: Top-Down Flow, Bottom-Up Flow, Stealth Flow" (T/F)
False
A SIPOC diagram is typically extends to more than one page.
False
A change (as opposed to a transition) includes a long period of adjustment (T/F)
False
A green belt should address common cause variation before special cause variation. (T/F)
False
A process can be capable, but not in statistical control. (T/F)
False
A swim-lane flowchart shows how the material moves across the production floor. (T/F)
False
Audit measurement system studies assess repeatability and reproducibility. (T/F)
False
Common cause variation is AKA assignable variation
False
Gage studies determine the ability of your measurement system to put items into correct categories consistently and reliably. (T/F)
False
Information is defined as raw facts, data is defined as facts in relationship, and knowledge as patterns or trends in data. (T/F)
False
It is best to determine key process variables, output, and inputs before creating a AS IS Value Stream Map (or other detailed process flowchart). (T/F)
False
Monitoring is a valid response to special cause variation in a capable process. (T/F)
False
Nominal Group Technique is a Six Sigma tool in which participants verbally share ideas then nominate the best idea. (T/F)
False
Poka-Yoke is a visual indicator that more material is required. (T/F)
False
See Q2_Question Two Image - It is a Quality Function Deployment (QFD) House of Quality for a Smart Phone: Based on this Quality Function Deployment (QFD) House of Quality, Glass is positively correlated with Camera Piece. (T/F)
False
Short-term process capability index determines if a process is capable and centered. (T/F)
False
Short-term process capability ratio determines if a process is capable and centered. (T/F)
False
Six Sigma is a war on waste and Lean is a war on variation. (T/F)
False
Which drop-down Minitab menus would you use to manage the data in a data set? File, Edit, Data, Calc Help, Assistant, Additional Tools Stat, Graph, View
File, Edit, Data, Calc
An Ishikawa diagram is also known as: Scatter diagram Fishbone diagram Process map Box plot
Fishbone diagram
All of the factors that might be contributing to a production problems must be discovered. Which of the following problem-solving tools would be the best selection? Control charts Histograms Fishbone diagrams Pareto diagrams
Fishbone diagrams
An activity is value-adding if it has the following characteristics. (3 correct) It changes (transforms) the product It is done right the first time The customer recognized value from the activity It has gone through a Kaikaku analysis It employs Kanban cards
It changes (transforms) the product It is done right the first time The customer recognized value from the activity
What is the concept of a "dashboard"?" The metrics of a process are displayed like an automobile It shows only what happened after the fact It shows lead and lag metrics that are critical to monitor It shows how to improve a metric
It shows lead and lag metrics that are critical to monitor
Lean Production that utilizes a pull system is easiest to implement in which environments? (2 correct) MTS ATO MTO ETO
MTS ATO
The input categories for a cause and effect (Ishikawa) diagram would NOT include: Maintenance Manpower Material Machine
Maintenance
All of the following are tips for minimizing data collection errors EXCEPT: Provide clear and complete instructions.. Multiple points of data entry for cross-checking. Calibration schedule. Carefully constructed data collection plan.
Multiple points of data entry for cross-checking.
Which statement best defines the goal of the measure phase? Pinpoint the location or source of the problem as precisely as you can and set a baseline capability. Describe and quantify both the defect and the expected improvement. Improve the process to eliminate defects. Determine the root cause of the defect.
Pinpoint the location or source of the problem as precisely as you can and set a baseline capability.
What information does the "Roof" of the house in Quality Function Deployment (QFD) provided? Customer wants Customer needs Weighted scores Process Capabilities Process synergies
Process synergies
All of the following tools help us move from the "trivial many" to the "vital few" EXCEPT: Ishikawa Diagram Project Charter Pareto Analysis Cause-and-Effect Matrix
Project Charter
A work package is:
Represents a deliverable to be produced in a project
Difference Between Six Sigma and Lean
SIX SIGMA focuses on REDUCING process variation and ENHANCING process control LEAN drives OUT waste (non-value-added activities) and PROMOTES work standardization and value stream mapping
Which Lean term focuses on rapid change-over, or minimal setup time? SMED Kaikaku Gemba Kaizen Poka-Yoke
SMED
Which of the following would be visible Costs of Poor Quality (COPQ)? (2 correct) Scrap Inspection Late Deliveries Extra Inventory Lost Sales
Scrap Inspection
A cause-and-effect matrix is a problem-solving tool which helps to: Focus attention on process problems in priority order. Show relationships between input and output variables. Determine where nonconforming part exists. Generate a large number of improvement ideas.
Show relationships between input and output variables.
A cause-and-effect matrix is a problem-solving tool which helps to: Generate a large number of improvement ideas. Show relationships between input and output variables. Focus attention on process problems in priority order. Determine where nonconforming part exists.
Show relationships between input and output variables.
Kanban
Signal for a particular action including "obtain inventory," "produce part," or "move material from the upstream point to the downstream process." Kanban also ensures that no defective pieces are allowed to pass or be transferred.
Which of the following in NOT part of 5s? Shine Sustain Sort Simplify
Simplify
5S
Stands for sort (seiri), straighten (seiton), shine (seiso), standardize (seiketsu), and sustain (shitsuke), is used to create order and organization.
Which of the following statistical terms statements is correct? Populations come from samples. Samples come from statistics. Statistics come from samples. Populations come from statistics.
Statistics come from samples.
The most difficult stage for any team to work through is: Performing Forming Norming Storming
Storming
Pallets of product are staged in a warehouse prior to shipment. There are indications that damage is occurring disproportionately at the aisle and row end locations. The best method of data collection to confirm this theory would be: Skip-lot sampling. Stratified sampling Sequential sampling. Random sampling.
Stratified sampling
Pallets of product are staged in a warehouse prior to shipment. There are indications that damage is occurring disproportionately at the aisle and row end locations. The best method of data collection to confirm this theory would be: Stratified sampling Skip-lot sampling. Sequential sampling. Random sampling.
Stratified sampling
Process capability is defined as: Small variation. A process with no special cause variation. The ability of the process to meet specifications. A kappa score of 70% or greater.
The ability of the process to meet specifications.
Process capability is defined as: The ability of the process to meet specifications. A kappa score of 70% or greater. Small variation. A process with no special cause variation.
The ability of the process to meet specifications.
What is the correct definition of linearity in a measurement system? - The measurement system remains centered over time. - The part of measurement system variation that occurs when you repeated the measurement along a straight line. - The centering and the magnitude of the measurement system variation are consistent across the systems' range of operation. - The measurement system demonstrates a consistent offset from the actual characteristic being measured.
The centering and the magnitude of the measurement system variation are consistent across the systems' range of operation.
Where do you start six sigma? From the quality director The executive sponsor decides It's a bottom-up approach Middle management
The executive sponsor decides
Consider the following data set: 3, 4, 7, 7, 8, 11, 12, 13. Which of the following are factual statements regarding the data? The mean is less than the median. The median is less than the mode. The mode and the median are the same. The mean is greater than the mode.
The mean is greater than the mode.
Effective team meetings would typically NOT include: "The meeting time, frequency and location." The development of an agenda. The distribution of minutes. The participation of upper management.
The participation of upper management.
A short-term process capability index with a value of zero means: The process mean equals the upper specification limit. The process mean is less than the upper specification limit. The upper specification limit minus the mean is equal to three standard deviations. The process mean is greater than the upper specification limit
The process mean equals the upper specification limit.
What is y = f(x1 x2 ... xn) + ϵ?
The six sigma transfer function
For the normal probability distribution, the relationships among the median, mean, and mode are: They are all equal to the same value. Each has a value different from the other two. The mean and median are the same but the mode is different. The mean and the mode have the same value but the median is different.
They are all equal to the same value.
A process map is used to accomplish which of the following? Graphically display possible causes of problems in a process in groups, or categoies. Focus attention on process problems in priority order. "Track products, operator actions, or administrative procedures." Display a dynamic picture of process performance behavior.
Track products, operator actions, or administrative procedures.
"The primary purpose of the Measure phase is to assess the current performance of the process, validate the data, and establish a baseline." (T/F)
True
"The work package ""Collect the Voice of the Customer"" is part of the Define phase." (T/F)
True
A Type II measurement system error is accepting defective parts. (T/F)
True
An example of essential-non-value-added (or business-non-value-added) time would be an inspection step required by a regulation. (T/F)
True
ISO 9000:2000 defines a process a set of interrelated or interacting activities that transforms inputs into outputs. (T/F)
True
In a FMEA, the RPN is the severity rating times the occurrence rating times the detection rating. (T/F)
True
Kanban is a indicator that more material is required. (T/F)
True
Measurement systems introduce variation into observed data. (T/F)
True
Six sigma can be described as a war on variation (T/F)
True
The leadership best suited to a Six Sigma team in the Perform stage is Delegating. (T/F)
True
The primary purpose of a SIPOC diagram is to define the Six Sigma project's scope. (T/F)
True
Theory of Constraints is a problem solving method that focuses on the weakest (slowest or constraining) link in a chain of processes. (T/F)
True
From a Lean perspective, a process step does not add value then it is _____. Misaligned Inefficent Incorrect Waste
Waste
What required element is missing from the following Precision Delivery Incorporated (PDI) Problem Statement? Return on Sales (ROS) percent is insufficient to sustain business operations and create growth based on actual performance during the past three months. Last month, sales rebates were $9,400 and idle time costs of $3,600. These losses have degraded Profit Before Tax (PBT) by $13,000, lowered ROS, and caused customer dissatisfaction. - The size or magnitude of the problem. - Where the problem is occurring by process name and location. - A brief description of the problem and metric use to the describe the problem - The time frame over which the problem has been occurring.
Where the problem is occurring by process name and location.
Standard Work
applies capacity resource planning to determine the most efficient combinations of operations.
A marginal, but not good, gage will have a ratio of measured variation to observed variation that: is greater than 0.3 is less than 0.1 equals 1.0 is between 0.1 and 0.3
is between 0.1 and 0.3
Total Productive Maintenance
manages operations with preventive maintenance, load balancing, and streamlined flow control
Poka-Yoke
mistake-proofing by design and can include sizing devices, limit switches, color signals, and alarms.
Kaizen
pursues low-cost gradual improvement of processes either on an ongoing basis or as a dedicated endeavor known as a kaizen blitz.
Pull Systems
refers to production scheduling techniques where materials are staged at the point of consumption or application, and restocking is limited to only the amount that has been consumed by the process, avoiding the accumulation of excess inventory.
Special Causes
—Causes of variation that arise because of special circumstances. They are not an inherent part of a process. AKA "assignable causes"
