LSCM 355

ACME Anvil Corporation has done extensive analysis of their current process and found the following costs associated with the quality of their products and their revenue for the period: Based on these figures, what is the total cost of Prevention Costs? $10,000 $40,000 $50,000 $60,000

$10,000

ACME Anvil Corporation has done extensive analysis of their current process and found the following costs associated with the quality of their products and their revenue for the period: Based on these figures, what is the amount of the Internal Failure Costs? $155,000 $135,000 $290,000 $365,000 *Look at google doc*

$290,000

In the image below, the diagram on the right would have a higher or lower standard deviation? Lower Higher

Higher

How can organizations use general VOC feedback? To gauge overall customer satisfaction To identify specific problems with a process To test new products or ideas To get clarification about previous feedback recieved

To gauge overall customer satisfaction

What is the main goal of Just-in-Time (JIT) manufacturing? To produce an output "just in time" or "as needed" by the customer To produce an output in advance of customer demand To produce an output at a slower pace than customer demand To produce an output in large quantities for future use

To produce an output "just in time" or "as needed" by the customer

A best practice in Lean Six Sigma is that the roles and team structure are tailored to the project or process and should not be overly rigid. True False

True

All muda can be divided into two overall types: Type I and Type II. True False

True

Almost any process in a business will be dependent upon one or more other processes. True False

True

A pictorial representation of the items, events, and people required to produce an end result is called: a. Value Stream Map b. Voice of the Customer c. Process Control Chart d. Fishbone Diagram

Value Stream Map

ACME Anvil Corporation has done extensive analysis of their current process and found the following costs associated with the quality of their products and their revenue for the period: Based on these figures, what is the amount of the External Failure Costs? $1,450,000 $1,525,000 $1,550,000 $1,680,000 *Look at google doc*

$1,525,000

ACME Anvil Corporation has done extensive analysis of their current process and found the following costs associated with the quality of their products and their revenue for the period: Based on these figures, what is the CoPQ for this period? $1,815,000 $1,825,000 $1,865,000 $1,875,000 *Look at google doc*

$1,815,000

ACME Anvil Corporation has done extensive analysis of their current process and found the following costs associated with the quality of their products and their revenue for the period: Based on these figures, what is the total Cost of Quality for the period? $1,815,000 $1,825,000 $1,865,000 $1,875,000 *Look at google doc*

$1,875,000

ACME Anvil Corporation has done extensive analysis of their current process and found the following costs associated with the quality of their products and their revenue for the period: Based on these figures, what is the total cost of Appraisal Costs? $10,000 $40,000 $50,000 $60,000 *Look at google doc*

$50,000

ACME Anvil Corporation has done extensive analysis of their current process and found the following costs associated with the quality of their products and their revenue for the period: Based on these figures, what is the total Cost of Quality expressed as a percent of sales for the period? 15.00% 14.60% 14.92% 14.52% *Look at google doc*

15.00%

A process that is running at a Six Sigma level will have how many defects per million opportunities a. 1.7 b. 2.8 c. 3.9 d. 3.4

3.4

A textile printing company produces shirts. Their quality control found 699 defects last week. Each shirt has 20 opportunities for a defect in their process. If the company produces 7,500 shirts, what is their Sigma level using the partial Sigma Conversion Table? *Look at google sheet* a. 4.1 b. 3.7 c. 3.9 d. 4.3

4.1

A loan processor outputs 7,500 loans per week. Each loan has 10 opportunities for error. The QA process for the company found that the process resulted in 112 total errors for the week. Calculate the yield percentage for this process (rounded to the nearest 100th). a. 99.94% b. 99.48% c. 99.85% d. 98.91%

99.85% (7500*10= 75,000 - 112= (74,888 / 75,000)* 100 = 99.85%)

The following diagram was created to define the timeline of each step in the project in weeks. Which path is the critical path for this project? ABDG ABEG ACEG ACFG

ACFG

Scrum is a project development method specific to what type of project? Lean Process Management Total Quality Management Agile programming The Customer Experience Method

Agile programming

Common barriers to support for Lean Six Sigma implementation include: a. Leaders willing to pursue improvements initially but who lose interest in overseeing and championing project before they are completed b. All of the Above c. Department heads or employees who constantly champion their own process and needs and are unwilling to enter into big-picture thinking d. Employees who are resistant to change because they believe improvements might make them obsolete drastically change their jobs, or make their jobs harder

All of the above

Organizations should only launch projects that they can: Fund Support with people resources Manage All of the above

All of the above

Which of the following is a solution to reduce the waste of waiting in a process? Increasing the production of a single element Balancing machinery, people, and production Maintaining unreliable processes Allowing work to be batched in large quantities

Balancing machinery, people, and production

Using the information below, calculate the RTY of the total process (A through C). Express answers in percentage (without the symbol - e.g. 46.23 NOT 0.4623) round to two decimals. You can calculate the totals manually or use the spreadsheet below to do your calculations. *Look at google sheet*

Between 84.239 and 84.23

Using the information below, calculate the FTY of the total process (A through C). Express answers in percentage (without the symbol - e.g. 46.23 NOT 0.4623) round to two decimals. You can calculate the totals manually or use the spreadsheet below to do your calculations. *Look at google sheet*

Between 91.789 and 91.78

How can Six Sigma help reduce muda of cash? By fostering all ideas in a safe environment By encouraging subject matter experts to contribute By investing in upgrades and improvements WITHOUT analysis to identify opportunities By utilizing statistical analysis in decision-making

By utilizing statistical analysis in decision-making

The use of Six Sigma tools, measurements, and statistics after an improvement has been implemented to ensure that the process remains within the desired statistical boundaries is called: Understanding the Process Controlling the Process Automating the Process Continued Implementation

Controlling the Process

The cost of internal rejection and scrap of products is considered to be a part of which metric? Critical to Delivery (CTD) Cost of Poor Quality (COPQ) Critical to Quality (CTQ) Critical to Process (CTP)

Cost of Poor Quality (COPQ)

Which of the following is NOT one of the foundational principles of Toyota's production system and Lean Process Management? Creating a radical change across an entire organization or process architecture. Defining customer values. Identifying the value stream for customer needs and desires. Identifying waste in the process.

Creating a radical change across an entire organization or process architecture.

Which methodology would a Lean Six Sigma team use to approach this project? A business wants to create a smartphone app to help customers make and manage appointments. Business Process Management (BPM) DMAIC Just-in-time (JiT) DMADV

DMADV

Which methodology would a Lean Six Sigma team use to approach this project? A company that manufactures pizza boxes isn't happy with the profit margins in the small size boxes. Business Process Management (BPM) DMAIC Just-in-time (JiT) DMADV

DMAIC

Which methodology would a Lean Six Sigma team use to approach this project? A doctor's office has had numerous complaints from patients because it is too hard to get appointments, appointment communications are confusing, or patients show up for appointments and are told they don't have an appointment. Business Process Management (BPM) DMAIC Just-in-time (JiT) DMADV

DMAIC

A conclusion or formal judgement reached during a process that determine a course of action among various options is known as: Inputs Outputs Events Tasks Decisions

Decisions

What is the muda of ideas? Wasting time on unproductive tasks Not utilizing labor or staff efficiently Discounting and misappropriating thoughts and ideas Deciding not to invest in upgrades or improvements

Discounting and misappropriating thoughts and ideas

Specific, predefined criteria or actions that cause a process to begin working are known as: Inputs Outputs Events Tasks Decisions

Events

Our textbook states that ISO 9000 defines quality as the "degree to which a set of inherent characteristics fulfills requirements." Types of requirements include all of the following EXCEPT: Customer expectations Compliance or regularity rules Brand expectations Executive preferences

Executive preferences

5-Why analysis is time consuming and should only be used for complex or severe problems that can justify the time spent on the exercise. True False

False

A Lean Six-Sigma team can be pre-made and ready to begin work on any project that comes up in an organization. True False

False

A SIPOC diagram is a very detailed map of the process. True False

False

A Six Sigma team does not need to identify the processes related to a process improvement or project to define and maintain proper scope. True False

False

All components of a processes are independent. For example, a decision from a process cannot be an event that triggers another process. True False

False

Breaking each phase of DMAIC into smaller tasks makes team members feel like the project has too much work so it is recommended that the only milestones used for these projects are those at the end of each phase of DMAIC. True False

False

Conveyance waste only relates to the physical movement of items, not digital movement of data or workflow. True False

False

DMAIC methodology is used when developing a new process. True False

False

If a problem is already defined and a solution has been provided, you should still spend time going through the DMAIC phases. True False

False

In a Six Sigma organization, as the cost of poor quality goes down, the cost of good quality must go up. True False

False

Jidoka works to identify defects at the end of a production line or process to enable workers to trace the error back to the source. True False

False

Lean Six Sigma can be customized to any industry? a. True b. False

False

Lean Six Sigma is a combination of two improvement and quality control methodologies. Lean is concerned with bringing the process back within a state of statistical control while Six Sigma is a methodology that is used to eliminate waste. True False

False

Lean Six Sigma projects are separated from a formal change management process so do not have to be prepared to report to change management committees. True False

False

Manual data processes can cause challenges that make Lean Six Sigma implementation difficult. Automated data processes don't have any issues that can create challenges with Lean Six Sigma and are preferred for this reason. a. True b. False

False

Many of the individuals that sit on the group or council that typically oversees the Lean Six Sigma projects and culture in an organization also get involved in the day-to-day project details to ensure that the projects they are sponsoring or championing are going according to plan. True False

False

Process maps and documentation almost always provide better information about processing time than real-time observation. True False

False

The Likert Scale is a 10-point ranking system commonly used to gather data for statistical analysis. True False

False

Traditional project management techniques do not work with Lean Six Sigma teams so traditional project managers so not work on Lean Six Sigma teams. True False

False

Anything that enters a process or is required to enter a process to drive the creation of an output is known as a(n): Input Output Event Task Decision

Input

Just-in-Time manufacturing aims to reduce what kind of waste? Motion Waiting Defects Inventory

Inventory

Which of the following best describes the muda of motion? It refers to the excess production of goods or services beyond the demand. It occurs when materials or inputs are purchased or created before they are needed. It involves unnecessary movement or actions performed by employees during a process. It is the waste that occurs when there is a backlog or delay in processing work.

It involves unnecessary movement or actions performed by employees during a process

Which of the following best describes the muda of inventory? It occurs when materials or inputs are purchased or created before they are needed. It is a waste that occurs when products are produced at a slower pace than necessary. It refers to the excess production of goods or services beyond the demand. It is the waste that occurs when there is a backlog or delay in processing work.

It occurs when materials or inputs are purchased or created before they are needed.

What is one benefit of using a project viability model? It is less complicated than a selection matrix It provides some weighting for teams to make some criteria more important It doesn't require the input of the team It is completely objective in nature

It provides some weighting for teams to make some criteria more important

Sakichi Toyoda developed one of the core concepts of the Toyota Production System by introducing sensors that stopped an automatic loom if a piece of yarn snapped so that the operator could correct the issue without wasting material. This concept became known as: Kanban Just-in-Time Jidoka Kaizen

Jidoka

What types of charts are used in a combination chart in Excel to create a Pareto chart? Select all that apply. Note: This is based on my video - NOT on the instructions in the book. Pie chart Line chart Area chart Scatter plot Bar chart

Line chart Bar Chart

If measures of success are not properly defined, the team risks all of the following EXCEPT: Scope creep that affects the schedule timeline and budget Failing to satisfy the customer, sponsor, or team members Disagreement on the success or failure of the project Nothing really, we all have our own objectives in a project

Nothing really, we all have our own objectives in a project

Which of the following is NOT one of the seven types of waste (muda) according to Taiicho Ohno? Overproduction Correction Inventory Omission

Omission

Some activities and costs may fall into both appraisal costs and prevention costs. When this happens, one should: Count the cost twice, once in each category. Only count the cost once, choosing the category that makes the most sense. Don't count the cost at all as it is too obscure to include.

Only count the cost once, choosing the category that makes the most sense.

The products or services that are used by the customer of a process are known as: Inputs Outputs Events Tasks Decisions

Outputs

When completing a SIPOC diagram, what is the BEST swim lane to start with? Suppliers Inputs Process Outputs Customer

Process

Which of the following is NOT typically true of a process owner's responsibilities? Monitor how the process performs, usually using one or more metrics or regularly reported data elements. Understand how the process fits into the overall business, why the output of the process is critical to business goals, and what inputs feed the process. Ensures the process is documented via standard operating procedures (SOPs) and that process documentation is kept current and accurate. Ensures operators within the process have the resources and training they need to complete their jobs. Process owners are solely responsible for executing the process tasks themselves.

Process owners are solely responsible for executing the process tasks themselves.

Which of the following best describes overproduction? Producing a product, part, or service too slowly Producing a product, part, or service at the wrong time Producing a product, part, or service in too much quantity Producing a product, part, or service with high quality

Producing a product, part, or service in too much quantity

All of the following are types of team members on a Lean Six Sigma project EXCEPT: Regular team members Ad-hoc team members Project evangelists Resource team members

Project evangelists

Which of the following is an example of the muda of talent? Hiring the most skilled person for a task Putting staff in the wrong position Encouraging staff members to contribute their ideas Investing in upgrades and improvements

Putting staff in the wrong position

A call center providing scripts to employees with suggested comments for common scenarios is attempting to do what kind of continuous improvement? Reducing Variation Removing Waste None of the Above Centering the Process

Reducing Variation

What is a disadvantage of using social media as a Voice of the Customer (VOC) tool? Requires a lot of labor hours. Takes time and requires experienced users or testers. Requires an established social media following. Can't use data to make assumptions about the general population.

Requires an established social media following.

The Nine Boxes Model shown below is a matrix of three performance levels and three performance dimensions that is a foundational component of which quality or process improvement methodology? *Look at google sheet* Total Quality Management Rummler-Brache Six Sigma Scrum

Rummler-Brache

Which phase of the 5S methodology focuses on keeping the workplace clean and neat? Sort Straighten Shine Standardize Sustain

Shine

In response to the CEO of Motorola's request for improvement in quality and production, Bill Smith and Dr. Mikel Harry developed what methodology? Six Sigma Total Quality Management JumpStart The PDCA Cycle

Six Sigma

Which phase of the 5S methodology is used to maintain the progress achieved in all previous phases? Sort Straighten Shine Standardize Sustain

Standardize

What is an SME in regards to a process or work function? Social Media Expert Subject Matter Expert Sales and Marketing Executive Supply Management Expert

Subject Matter Expert

What are some methods for capturing Voice of the Customer (VOC) feedback? Statistical analysis and data modeling Hypothesis testing and regression analysis Process mapping and control charts Surveys, focus groups, and customer complaints

Surveys, focus groups, and customer complaints

The activities as the heart of a process are known as: Inputs Outputs Events Tasks Decisions

Tasks

The foundation of Six Sigma is a statistical concept known as: Correlation The Normal Probability Curve Regression Analysis Hypothesis Testing

The Normal Probability Curve

W. Edwards Deming utilized the statistical ideas of Walter Shewhart to create a concept that is one of the core tenets of Six Sigma called: Business Process Reengineering Rummler-Brache Control Charts The PDCA Cycle

The PDCA Cycle

A 5-Why analysis is used to determine which of the following? The defects per million opportunities (DPMO) The root cause or actual problem First time yield (FTY) Rolled throughput yield (RTY)

The root cause or actual problem

Match the description of each phase of the Lean Six Sigma method used with NEW processes: Design, Control, Verify, Define, Improve, Analyze, and Measure This phase is when teams use data to validate their assumptions about the process and the problem. During this phase, the team works to create a new process which includes some solutions testing, mapping, workflows, and new infrastructures. This phase is concerned with identifying the problem, defining requirements for the project, and setting goals for success. This phase is where loose ends are tied and the project is transitioned to a daily work environment. During this phase, teams develop hypotheses about causal relationships between inputs and outputs and between Xs and Ys, they narrow causation down to the vital few, and they use statistical analysis and data to validate the hypotheses and assumptions they've made so far.

This phase is when teams use data to validate their assumptions about the process and the problem. - Measure During this phase, the team works to create a new process which includes some solutions testing, mapping, workflows, and new infrastructures. - Design This phase is concerned with identifying the problem, defining requirements for the project, and setting goals for success.- Define This phase is where loose ends are tied and the project is transitioned to a daily work environment. - Verify During this phase, teams develop hypotheses about causal relationships between inputs and outputs and between Xs and Ys, they narrow causation down to the vital few, and they use statistical analysis and data to validate the hypotheses and assumptions they've made so far. - Analyze

Match the description of each phase of the Lean Six Sigma method: Design, Control, Verify, Define, Improve, Analyze, and Measure This phase is where loose ends are tied and the project is transitioned to a daily work environment. In this phase, teams start developing the ideas that began in the Analyze phase and continue testing hypotheses and solutions. This phase is concerned with identifying the problem, defining requirements for the project, and setting goals for success. During this phase, teams develop hypotheses about causal relationships between inputs and outputs and between Xs and Ys, they narrow causation down to the vital few (using methods such as the Pareto principle), and they use statistical analysis and data to validate the hypotheses and assumptions they've made so far This phase is when teams use data to validate their assumptions about the process and the problem.

This phase is where loose ends are tied and the project is transitioned to a daily work environment. - Control In this phase, teams start developing the ideas that began in the Analyze phase and continue testing hypotheses and solutions. - Improve This phase is concerned with identifying the problem, defining requirements for the project, and setting goals for success. - Define During this phase, teams develop hypotheses about causal relationships between inputs and outputs and between Xs and Ys, they narrow causation down to the vital few (using methods such as the Pareto principle), and they use statistical analysis and data to validate the hypotheses and assumptions they've made so far - Analyze This phase is when teams use data to validate their assumptions about the process and the problem. - Measure

Correction, or rework, is considered waste in a process that should be identified and analyzed. True False

True

It is impossible for any organization to remove 100% of quality costs. True False

True

JumpStart methodology should not be used by itself for sweeping changes or to improve processes that could seriously impact customer experience or the bottom line because it does not take the time for rigorous verification or statistical analysis. True False

True

Organizations should look at both internal and external sources of information when reviewing the current state of the organization for improvement opportunities. True False

True

Some small to mid-size organizations can have concerns with Lean Six Sigma implementation because they do not have the resources with training and expertise to successfully commit to the process. True False

True

Standard deviation serves as a pointer for where to investigate within the process for problems or solutions and it is involved in many of the other statistical processes. True False

True

There are often costs associated with poor quality that are hidden or difficult to determine. True False

True

In which situations are Pareto charts particularly useful? When addressing problems that have a specific identified cause When creating scatter plots When addressing broad problems When conducting hypothesis testing

When addressing broad problems

Which of these is NOT a reason to choose Six Sigma over other methods described in the textbook? When costs are closely tied to processes. When solving complex problems. When problems are widespread and not defined. When you know the root cause of the problem.

When you know the root cause of the problem.

Disadvantages to beta testing without utilizing Six Sigma methodology include all EXCEPT: a. Money may be spent on ideas that don't end up working out as planned b. customer perception can be impacted through trial-and-error periods rife with opportunities for error c. It increases the risk and cost inherent in launching an unproven product or system to a widespread audience d. Organizations can experience unintended consequences from changes

c. It increases the risk and cost inherent in launching an unproven product or system to a widespread audience