IASSC - Yellow Belt Practice Questions
The Seven Wastes (Muda)
(1) Overproduction (2) Waiting (3) Transportation (4) Inappropriate processing (5) Unnecessary inventory (6) Unnecessary motion (7) Defects
Elements of a good Project Charter
(1) Problem Statement (2) Project Charter Goals and Objectives (3) Business case (4) Project scope (5) Project Charter Milestones (6) Stakeholders (7) Constraints & Dependencies (8) Roles & Responsibilities of team members
The largest observation is 5.0 and the smallest observation is 2.0, what is the Range of the data? (A) 3 (B) 7 (C) 2.5 (D) 4
(A) 3
The Primary Metric is the (A) Actual measure of the Defect (B) First Stakeholder's suggestion (C) View of the project team (D) Objective received from the General Manager
(A) Actual measure of the Defect
Usually a Cause & Effect Diagram is used to document the output of a (A) Brainstorming session (B) Process Map (C) Design of Experiments (D) SPC Chart
(A) Brainstorming session
In a road transport company which of these activities can be considered as Value-Added? (A) Driving (B) Copying the customer's address from the information system onto the driver's notebook (C) Arrangement of goods into the vehicle body (D) Refueling the truck (E) Preparation of the delivery schedule
(A) Driving
What is a 5S concept that emphasizes putting critical information at the point of need? (A) Clean Desk Policy (B) Visual Workplace (C) Daily Huddle Board (D) Audits
(A) Driving
The primary objective of Lean is (A) Efficiency (B) Accurate data analysis (C) Reduction of variation (D) Risk management
(A) Efficiency
What tool is used to focus attention on the more critical sources of "pain" in a process? (A) Pareto Chart (B) Binomial Distribution (C) Control Chart (D) Normal Distribution
(A) Pareto Chart
All components of Accuracy are (A) Stability, Linearity, Resolution, Bias (B) Repeatability & Reproducibility (C) Stability & Linearity (D) Resolution & Bias
(A) Stability, Linearity, Resolution, Bias
Which one of these is the objective when performing a Financial Evaluation? (A) To establish the value of the Project (B) To clearly establish the Finance Department point of view (C) To clearly establish the Manufacturing Department point of view (D) To motivate the entire Team
(A) To establish the value of the Project
What are the most common tests used in Six Sigma to test Normality of the data? (A) Normality Plot (B) Anderson Darling, Goodness of Fit, Normal Probability (C) Box Plot, Scatter Plot, Hypothesis Testing (D) Scatter Plot, Anderson Darling, Histogram
(B) Anderson Darling, Goodness of Fit, Normal Probability
Which of these are standard symbols used in Process Mapping? (A) Arrows, Lines, Squares, Dots (B) Arrows, Rectangles, Diamonds, Circles (C) Dots, Statistics, Rectangles, Circles (D) Squares, Symbols, Hashtags, Circles
(B) Arrows, Rectangles, Diamonds, Circles
What is the difference between DPU and DPO? (A) DPU - Distribution Per Unit, DPO - Defects Per Opportunity (B) DPU - Defects Per Unit, DPO - Defects Per Opportunity (C) DPU - Distribution Per Unit, DPO - Defects Per Output (D) DPU - Defects Per Unit, DPO - Defects Per Output
(B) DPU - Defects Per Unit, DPO - Defects Per Opportunity
The primary reason most companies implement Six Sigma is to (A) Reduce defects (B) Each of these is correct (C) Improve processes (D) Improve profit
(B) Each of these is correct
Who is credited for the use of the word "Lean" in Lean Manufacturing in the 1990's? (A) W. Edwards Deming (B) James Womack (C) Jack Welch (D) Shigeo Shingo
(B) James Womack
Traditionally Seven Wastes, also known as Muda, include (A) Inventory count efforts (B) Overproduction (C) Data gathering (D) Personnel stress analysis
(B) Overproduction
The best definition of Standardized Work is (A) Doing things the same way every time (B) The documentation and practice of using the best, safest and easiest method to do a job (C) The practice of doing things the way your customer would like (D) Running an operation at the speed needed to satisfy customer demand
(B) The documentation and practice of using the best, safest and easiest method to do a job
The Cpk for a process with an average of 28, a Spread of 10 units and upper and lower specification limits of 35 and 15 respectively would be (A) 1.0 (B) 1.2 (C) 0.23 (D) 1.6
(C) 0.23
Jane, a Black Belt, is in the process of finding reasons for embarking on an improvement project. She is checking if the improvement project is linked to the company's key success factors and objectives. She also is looking into which key process output measure(s) will the project leverage as well as looking into the rough estimates on cost savings/opportunities for the improvement project. What is she trying to build here? (A) A CTQ Tree (B) A Project Charter (C) A Business Case (D) A Problem Statement
(C) A Business Case
Features that set Six Sigma apart from previous quality-improvement initiatives include (A) A clear commitment to making decisions on the basis of assumptions and guesswork (B) Making a SIPOC (C) A clear focus on achieving measurable and quantifiable financial returns (D) An increased emphasis on strong and passionate Black Belts
(C) A clear focus on achieving measurable and quantifiable financial returns
A process has a defect rate of 12.7%. A Lean Six Sigma breakthrough aims at reaching 1%. Such a goal is (A) Acceptable because it is highly challenging (B) Not ambitious enough because Six Sigma aims at much lower defect rates; 3.4 DPMO typically (C) Acceptable if such an improvement is of strategic importance and adequate resources are provided to the project (D) Unrealistic in one single project
(C) Acceptable if such an improvement is of strategic importance and adequate resources are provided to the project
The period for calculating the savings from a project is 12 months starting (A) At the end of the Measure Phase (B) When the Project Charter is signed off by the Sponsor (C) After the improvements have been implemented (D) When the process exhibits Stability
(C) After the improvements have been implemented
Measuring performance on a Six Sigma scale encompasses (A) Only the variation in calculations (B) Only the average in calculations (C) Both the average and variation in calculations (D) None of these is correct
(C) Both the average and variation in calculations
Both Primary and Secondary Metric(s) should be (A) Measured once at the beginning and end (B) Measured according to the suggestion of the Process Owner (C) Continually measured and frequently updated during the lifecycle of a Project (D) Measured twice with each process change
(C) Continually measured and frequently updated during the lifecycle of a Project
A Run Chart with statistically-based limits is known as a (A) Scatter Diagram (B) Box and Whisker Plot (C) Control Chart (D) Pareto Chart (E) Dot Plot (F) Histogram
(C) Control Chart
The X-Y Diagram (matrix) is created to (A) Generate a Fitted Line Plot (B) Map the Voice of the Customer to a specification (C) Explore potential relationships between inputs and outputs (D) Calculate the existing process Capability
(C) Explore potential relationships between inputs and outputs
Listening to the customer normally means the (A) Intermediate user (B) CEO (C) External customer (D) Marketing department
(C) External customer
As a consequence of a project a production machine could be sold. The amount of the sale should be (A) Included in the soft savings of the project (B) None of these is correct (C) Included in the hard savings of the project as a "one-time" revenue source (D) Not included in the savings of the project
(C) Included in the hard savings of the project as a "one-time" revenue source
The Problem Statement is the (A) Stakeholder's view of the issue (B) Concern within the Engineering Department (C) Pain caused by a defect (D) Non-conformity raised by the Quality Department
(C) Pain caused by a defect
The ________ is (are) in charge of applying and monitoring the Control Plan. (A) Black/Green Belt (B) Project Champion (C) Process Owner (D) External auditors (E) Quality Department
(C) Process Owner
Which step in 5S helps to instill discipline necessary to avoid backsliding on work completed? (A) Standardize (B) Sort (C) Sustain (D) Straighten
(C) Sustain
A process basically revolves around the customer. Each activity must therefore (A) Add inventory (B) Be subject to continuous improvement (C) Be part of an FMEA (D) Add value
(D) Add value
Why should a belt assess the Normality of the data? (A) To be sure data are Normally Distributed (B) Because Normality will simplify the use of data tools (C) To detect Non-value Add activities (D) Because understanding if the data are Normal will impact how we assess the data
(D) Because understanding if the data are Normal will impact how we assess the data
Monitoring is a key element of a (A) 5 Why Analysis (B) Process Map (C) Cause & Effect Diagram (D) Control Plan
(D) Control Plan
What term best describes the definition: A mapping process that helps to create measurable characteristics of a service to a customer? (A) Critical to Customer tree (B) Critical to Process tree (C) Critical to Business tree (D) Critical to Quality tree
(D) Critical to Quality tree
Elements of a Value Stream Map include all of the following except (A) Data streams that enter any process step (B) Both value add and non-value add activities (C) Resource counts used at a step (D) Detailed desk procedures
(D) Detailed desk procedures
Mistake Proofing (Poka-yoke) applies to processes with (A) Variable data types alone (B) Robotic input only (C) Attribute data types alone (D) Human input only
(D) Human input only
Which of the following is one of the objectives of graphing data? (A) Simplify Brainstorming (B) Clarify Team Member selection (C) Find out statistical significance (D) Identify potential relationships between variables
(D) Identify potential relationships between variables
What is the frequency diagram that shows the contribution to a problem in a process? (A) Yamazumi Diagram (B) Flowchart (C) Takttime Diagram (D) Pareto Chart
(D) Pareto Chart
When two inspectors measuring the same object with the same instrument get differences in outcomes this is an error of (A) Linearity (B) Accuracy (C) Precision (D) Reproducibility (E) Repeatability
(D) Reproducibility
What is a RPN in a FMEA? (A) Rejections Process Number (B) Robust Project Plan (C) Risk Process Number (D) Risk Priority Number
(D) Risk Priority Number (FMEA is Failure Mode & Effect Analysis)
% Defective and PPM (DPMO) are metrics used to measure which of the following? (A) The number of Common Causes (B) The number of Special Causes (C) The ratio between Common and Special Causes (D) The Defect rate of the process
(D) The Defect rate of the process
Linearity is defined as (A) The shortest distance between two points (B) The straight distance between the Mean and Median when the distribution is Non-normal (C) The requirement for the surface size of the measuring device (D) The difference in Bias values throughout the measurement range in which the gage is intended to be used
(D) The difference in Bias values throughout the measurement range in which the gage is intended to be used
VOC data can be obtained in a reactive and/or proactive way with each of the following EXCEPT: (A) Customer interviews (B) Feedback forms (C) Market research (D) Customer surveys (E) Market leadership
(E) Market leadership
Who should be informed in case a critical process parameter exceeds its assigned limits or threshold? (A) The customer (B) The project team (C) The Belt (D) The persons or service responsible for that abnormality (E) The persons or service indicated in the Response Plan
(E) The persons or service indicated in the Response Plan
What is a Six Sigma level (with long-term 1.5 Sigma Shift)?
1 Sigma - 697,672 DPMO - Yield 30.9% - CPK 0.33 2 Sigma - 308,770 DPMO - Yield 69.1% - CPK 0.67 3 Sigma - 66,811 DPMO - Yield 93.3% - CPK 1.00 4 Sigma - 6,210 DPMO - Yield 99.4% - CPK 1.33 5 Sigma - 233 DPMO - Yield 99.98% - CPK 1.67 6 Sigma - 3.4 DPMO - Yield 99.9997% - CPK 2.00
Six Sigma Black Belt
100% allocated professional trained in DMAIC and other problem-solving methodologies. Has project management, statistical, and process analysis skill sets. Trained in the science of and soft skills needed to bring about change. Responsibilities often include training green belts and other black belt candidates and leading Six Sigma projects. Black Belts may also serve as internal consultants helping multiple teams at once. Job duties sometimes include training other employees in tools, techniques, and processes.
Six Sigma Master Black Belt
100% allocated professional with tremendous experience as a Black Belt, leading teams and completing projects. A true expert in Six Sigma methodology and tools. Six Sigma Master Black Belts often mentor aspiring black belts and consult and remove obstacles from Black Belt teams. They have a responsibility to champions for keeping a portfolio of initiatives on track.
Describe the Six Sigma timeline
1908 - Henry Ford - Mass Production 1924 - Walter Shewhart - Control Charts 1950 - Eiji Toyota - Toyota Production System (TPS) 1986 - Bill Smith - Developed Six Sigma 1995 - Jack Welch - Introduced Six Sigma to GE
Kanban
A Japanese word meaning "card" or "visible record" that refers to cards used to control the flow of production through a factory. A ticket-based JIT system that indicates when to reorder inventory
What is Six Sigma?
A framework designed to make an organization more competitive by defect elimination and variation reduction, leading to process improvement. It's all about getting to the root issue of defects and variation.
Six Sigma Green Belt
A professional with introductory Six Sigma training partially allocated to an initiative. Maybe a team member on a Black Belt project or lead a smaller project.
Attribute Gage R&R
Also known as Attribute Agreement Analysis
Analyze (DMAIC)
Analyze the data to determine the root causes of the problems and then identify opportunities for improvements.
Who coined the term "Six Sigma"?
Bill Smith, working at Motorola in 1986
Shine (5S)
Clean and wash the work area and make it shine
What is the difference between Cp, Cpk, Pp, Ppk?
Cp - Stable Process, Centered Cpk - Stable Process, Not Centered Pp - Unstable Process, Centered Ppk - Unstable Process, Not Centered
Sustain (5S)
Create discipline to perform the first four S practices, whereby everyone understands, obeys, and practices the rules when in the plant. Implement mechanisms to sustain the gains by involving people and recognizing them through a performance measurement system.
What three sections comprise a Critical to Quality (CTQ) Tree?
Customer requirement: This is what the customer might express to you as a concern. For example, "I like my coffee really hot and milky!" Drivers: The customer requirement is broken down into action points. For example, "High temperature" and "High percentage of dairy milk." CTQ requirements: These are your manufacturing guidelines to meet the drivers. For example, "Full-cream pasteurized dairy milk" and "Milk frother heats to at least 203°F".
What are the three key elements of Six Sigma?
Customers: Customers are the key to business, and they are the top priority. Customers define the quality requirements and expect on-time delivery, high performance, great service, and many more. However, meeting customer requirements is not enough in the business world. Process: Defining the process and important metrics is the key aspect of Six Sigma. Since the customer is key for any business, quality needs to be looked at from the customer's perspective. This helps to identify the gaps in processes and the work necessary to improve them. Employee: Without leadership commitment, using Six Sigma in any organization is difficult. The organization must involve all employees with well-defined roles and clear objectives. Furthermore, organizations must provide required resources like people, training, budget, and more.
Lean implementation emphasizes the importance of optimizing flow through strategic operational procedures while minimizing ________ and being ________. A. Costs, agile B. Resources, smart C. Floorspace, effective D. Waste, adaptable
D. Waste, adaptable
Define (DMAIC)
Define the problem and also project goals that need to be addressed.
DMADV
Define, Measure, Analyze, Design, Verify
What is DMAIC?
Define, Measure, Analyze, Improve, Control
Standardize (5S)
Establish schedules and methods of performing the cleaning and sorting. Formalize the cleanliness that results from regularly doing the first three S practices so that perpetual cleanliness and a state of readiness are maintained.
A process can have only Special Causes or Common Causes but not both. True or False?
False
A successful Six Sigma program should produce a decreased need for management efforts to maintain quality. True or False?
False
An FMEA is a "once-and-done" document without any further updates necessary. True or False?
False
Attribute Data is often referred to as quantitative data and can be measured on a continuum or scale. True or False?
False
Ishikawa is generally recognized as the creator of the Control Chart. True or False?
False - Walter Shewhart is generally recognized as the creator
Improve (DMAIC)
Improve the process and test the statistical solution.
Measure (DMAIC)
Measure the baseline performance and confirm the practical problem by collecting data
DMAIC Tollgate Review
Mechanism to review progress with sponsors and stakeholders and ensure the project is on course. Managers, sponsors, champions, master black belts, and other stakeholders participate in the tollgate review as the ultimate traffic light. In other words, they say whether the project is green to go for the next phase in DMAIC, or they stop you at red if more time is required to work out kinks. In some circumstances, management can discontinue the Six Sigma project if target goals are not met. Therefore, it is crucial that your tollgate presentation is clear and answers critical questions your audience may have. Can include Process Maps like SIPOC (Suppliers, Inputs, Processes, Outputs, and Customers), Financial Measures, CTQ (Critical to Quality) Measures.
Six Sigma Champion
Middle or senior executive who sponsors and promotes continuous improvement initiatives throughout their organization. Secures training and mentorship for Black Belt candidates and ensures that project resources are available. Resolves any cross-functional team issues that may occur. Trained in the basics of Six Sigma. Sometimes filled by former Black Belts or Master Black Belts. Occasionally the Champion may also Sponsor projects or programs.
Straighten (5S)
Neatly arrange what is left, with a place for everything and everything in its place. Organize the work area so that it is easy to find what is needed.
Design (DMADV)
Optimize design components and completes the design
What are two types of FMEA?
PFMEA (Process FMEA) DFMEA (Design FMEA)
Rolled Throughput Yield (RTY)
Probability that a product will pass through the entire production or service process without rework and defects
Six Sigma Process Owner
Professional, often a senior business leader, responsible for the business process that is the target of a Six Sigma project. Sometimes the process owner may be the sponsor of the initiative.
What is the formula for RTY (Roll Through Yield)?
RTY = FTY1 * FTY2 * ... * FTYn
What is a Gage R&R?
Repeatability - the variation between successive measurements of the same part, same trait, by the same person using the same gage. In other words, how much variation do we see in measurements taken by the same person, on the same part, using the same tool? Reproducibility - the difference in the average of the measurements made by different people using the same instrument when measuring the identical characteristic on the same part. In other words, how much variation do we see in measurements taken by different people on the same part using the same tool?
Control (DMAIC)
Start using a new process for production. Implement, control, and ensure sustainability. Finally, measure the new process based on customer reactions.
Anderson-Darling Test
Test of normality, goodness-of-fit
Binomial Distribution
The probability distribution of X with parameters n and p
What is a Project Charter?
The project charter is a set of documents that provide purpose and motivation for the project, serves as a working document for the team and as a reference for the rest of the company, and acts as a guiding hand for the Plan-Do-Study-Act cycle (Deming wheel, Shewhart wheel). Use it as a guide for managing the project, meeting production schedules, etc. It can also be a good method of problem identification as it clearly documents the scope and business impact of the problem the Six Sigma team is attempting to solve. The project charter should also clearly state the intended goals and how success will be measured.
Voice of Customer
To be certain on what they want, we reach out to our customers, clients, partners, and suppliers to ensure we hear what is really important to them. Can be proactive (mock-ups, beta versions, surveys, interviews) or reactive (online feedback, reviews, customer service logs).
What is FMEA (Failure Mode & Effect Analysis)?
Tool that helps us anticipate what might go wrong with a product or process. a "Failure Mode" is a chance for a process to go wrong. We use FMEA in the Analyze and Improve section of DMAIC.
Process Map
Tool that shows the inputs, actions, and outputs of a process in a clear, step-by-step map of the process
What is the formula for total variation?
Total Variation = Process Variation + Measurement Variation
A lot-making board involces creating a physical Kanban for every container of parts in the system. True or False?
True
As a company's Sigma level increases the Cost of Poor Quality decreases. True or False?
True
COPQ (Cost of Poor Quality) does not include detection and prevention cost. True or False?
True
If Y=f(x) the variable X is called the independent variable while the variable Y is called the dependent variable. True or False?
True
In a Lean Six Sigma organization the Sponsor allocates resources to projects in his unit, communicates frequently with the project manager and participates in DMAIC end-of-phase reviews. True or False?
True
Prior to performing an Attribute Gage R&R study each of the elements included in the study must be inspected by an expert in order to set the reference values. True or False?
True
The term Poka-yoke was applied by Shigeo Shingo in the 1960s to industrial processes designed to prevent human errors. True or False?
True
Six Sigma Sponsor
Usually a high-level or senior business leader or executive who sponsors the Six Sigma engagement. Responsible for articulating the problem statement, defining the team's objectives, and validating the business case in the project charter. Sponsors are the liaison between the team and senior management and are thus responsible for securing subject matter experts and non-Six Sigma resources critical to the success of the project. Is looked to for decisions at critical times in the project. The sponsor's approval is required at DMAIC tollgates.
Verify (DMADV)
Validate and quantify the design performance.
Causal Theory
Y = f(x) Output = Method * Input
bimodal distribution
a frequency distribution having two different values that are heavily populated with cases
Kaizen
continuous improvement; Kai = change, Zen = good
Sort (5S)
separate needed items from unneeded items and discard the unneeded
5S
sort, straighten, shine, standardize, sustain
Process Capability
the inherent variability of process output relative to the variation allowed by the design specification
