Lean six
A high level process map constructed in the Define Phase at a minimum must include: (check all that apply) start and stop points value categories directional flow all decision points all process steps
start and stop points value categories directional flow all decision points all process steps
Applying Statistical Process Control to only the process outputs is better known as ___________________________
statistical process monitoring
seiton
straighten
shitsuke
sustain
A VIF between 5 and 10 indicates
that the regression coefficients are poorly estimated and are unacceptable
A Multivariate Regression model with a high R-Squared value establishes a cause and effect relationship between the out response Y and the input variables X. T/F
false
A goal of the Pareto analysis in an LSS project is to assist you in determining what inputs have the least impact on your process. T/F
false
A process is a non-repetitive series of unorganized steps or activities where inputs are modified to achieve value-added output. T/F
false
A rental car agency is testing two brands of radial tires. The agency assigns one tire of each brand at random to the two rear wheels of eight cars and runs the cars until the tires wear out. The data provided below is in miles. Brand 1 Brand 2 36,925 34,318 45,300 42,270 36,745 35, 600 32,100 31,175 37, 250 38,470 48,390 47,600 38,200 37,950 33,500 33,225 Based on the data provided, your would prefer Brand 1 over Brand 2 at the 95% CL T/F
false
Conveyance is an element of waste. Conveyance is the necessary movement of material and goods. T/F
false
Cp is computed as: (closest Spec Limit - sample mean)/6S T/F
false
Cycle time is the "touch time" of the value added portion of the process. T/F
false
Cyclical variation is variation across a single unit containing many parts. T/F
false
DOE allows experimenters to study the effect of many input variables that may influence the product or process one at a time as well as identify possible interaction effects. T/F
false
Defect prevention seeks to gain permanency by adding human intervention. T/F
false
Discrete data is always more desirable for statistical analysis T/F
false
FMEA is an unstructured approach that is designed to help eliminate X's in your process. T/F
false
If a process is not capable then you must find a way to shift the process. T/F
false
If a process is not centered then you must find a way to reduce the variation. T/F
false
Kanban is a technique used to "push" products and material through the system. T/F
false
Measurement system analysis is only applicable to about 50% of projects and often times has an insignificant effect on the success of a project. T/F
false
Multi-Vari Carts can be used to assess capability, stability, and statistical relationships between X's and Y's. T/F
false
Narrowing the specification limits is a reasonable problem-solving option for an incapable process T/F
false
Poor Correlation allows for tighter tolerances T/F
false
Reproducibility is the variation in measurements obtained by one individual measuring the same characteristic on the same item with the same measuring instrument. T/F
false
SPC is used to detect common cause variation telling us the process is "out of control" T/F
false
Six Sigma created a realistic and quantifiable goal in terms of its target of 3 defects per million operations. T/F
false
Six Sigma makes people into statisticians in order to be excellent problem solvers. T/F
false
Six Sigma starts with a practical problem, translates it into a statistical problem, corrects the practical problem then validates the statistical problem. T/F
false
The amount of difference, change, or improvement that will be of economic or technical value to you is known as statistical significance. T/F
false
The central limit states that as the sample size becomes large, then the sample mean distribution will form a normal distribution only if the population distribution of individuals is normally distributed T/F
false
The interquartile range is the difference between the 90th percentile and the 30th percentile. T/F
false
The least common operator/machine errors have to do with someone misreading a value, recording a value incorrectly or the fixture holding the part is poor. T/F
false
The level 2 process flow map usually contains estimates of defects-per-unit, flow throughput yield and roll throughput yield T/F
false
The primary purpose of linear correlation is to measure the strength of a non-linear association between two variables (X and Y) T/F
false
The regression equation with a high R-squared value identifies a strong cause and effect relationship. T/F
false
The second stage of 5S, Shining, is keeping everything clean and swept T/F
false
The strength of the "lean" concept is effectiveness. T/F
false
The three components of a financial evaluation are Impact, Forecast, and KPI's T/F
false
Two different etching solutions are being compared for a semiconductor manufacturing process. The etch rate is known to follow a normal distribution. Using two random samples of 10 Wafers for each etch solution, the following etch rates were observed: Sample 1 9.9, 9.4, 9.3, 9.6, 9.8, 10.2, 10.4, 10.3, 10.1, 10.0 Sample 2 10.2, 10.6, 10.7, 10.4, 10.0, 10.2, 10.4, 10.2, 10.5, 10.3 The data supports the claim that the mean etch rate is the same for both etching solutions at the alpha=0.05 level. T/F
false
Unit to Unit Variation is a type of measurement system error. T/F
false
We can sustain a visual factory without 5S T/F
false
When selecting projects, the starting point is defined by the Champion or process owner with the Benefits analysis as the output. T/F
false
When studying two samples, there may be a real difference between the two samples; however, we may not be able to determine s statistical difference. Our ability to detect a difference is only driven by the sample size? T/F
false
When the average of a set of measurements is on target we say the measurement is precise. T/F
false
When viewing an interaction plot, the lines must actually cross each other in the figure for an interaction to exist? T/F
false
for our process, Y = f (xi) if we are good at controlling and choosing the xi's then we need to constantly test and inspect Y? T/F
false
First Time Yield is the appropriate metric for problem solving because it accounts for any necessary rework. T/F
false (Rolled Throughput Yield, RTY is the most appropriate metric for problem solving because it accounts for losses due to rework)
In a Six Sigma organization aA Green Belt serves as the Project Team lead, facilitates DMAIC teams in applying Six Sigma methods, works cross functionally, contributes to the organizational goals, and provides technical support to improvements efforts. T/F
false (black belt)
A Master Black Belt (MBB) owns project selection, execution control, implementation and realization of gains. T/F
false (champion)
In process mapping, a parallelogram indicates an activity. T/F
false (decision)
A crossed design is used for destructive testing and also situations where it is not possible to have all operators or machines measure all the parts multiple times. T/F
false (nested is destructive)
In a six sigma process, it is necessary to clearly understand the customers needs, we call this "understanding the CTp's or Critical to Process. T/F
false (should be CTQ critical to customer)
Bartlett's Test is used to compare the estimated population standard deviations from two or more samples with Non-Normal Data T/F
false (should be levins)
What type of DOE design is used when the process or product knowledge is low and there is a long list of possible input variables.
fractional factorial
Which of the following are the primary causes for Non-Normal Data? (check all that apply) ? granularity of data natural and artificial limits multiple modes kurtosis
granularity of data natural and artificial limits multiple modes kurtosis
Process Interruptions are mechanisms installed that shut down the process and prevent further operation until a required action is completed. Which of the following is an example of a process interruption
ground fault interrupt
Which of the following reasons for a designed experiment creates a mathematical model designed to move the process response. problem solving screening optimizing robust design
optimizing
Capability is defined as:
output variation width divided by specification width
The ___________ chart plots the proportion of nonconforming units collected from subgroups of equal or unequal size.
p
Which of the following types of process control that are in place to prevent failure? (check all that apply) kaizen poke-yoka spc 5s
poke-yoka spc
Which of the following are not categorical headings for a product in a cause and effect diagram (check all that apply) measurement policy people place method
policy place
Poor measures can result from: (check all that apply) representative poor sampling inaccurate measurement devises relevant poor or non existent operational definitions difficult measures
poor sampling inaccurate measurement devises poor or non existent operational definitions difficult measures
VOE is "_______" Driven
process
Which of the following constitute the minimum set of deliverables for a project: (Select all that apply) detailed schedule project charter benefits analysis business case
project charter benefits analysis business case
Which of the following are potential roadblocks to an LSS project? project is scoped too broadly no historical data exists the team creates the "as is" process map excess inventory the team creates the "ideal" process map team members have time to collect data
project is scoped too broadly no historical data exists the team creates the "ideal" process map
Which of the following is not a measure Accuracy? repeatability resolution bias stability
repeatability
_________________ is the variation in measurements obtained with one measurement instrument used several times by one operator while measuring the identical characteristics on the same part.
repeatability
Appropriate measures are: (check all that apply) Representative Static Relevant Sufficient Contextual
representative relevant sufficient contextual representative
Generally speaking, COPQ can classified a tangible ( Visible, easy to see) and intangible (Hidden, difficult to see). Which of the following are examples of visible costs? late delivery rework warranty inspection lost sales
rework warranty inspection
Which of the following reasons for designed experiments desensitizes the output response to input variable changes including noise variables.
robust design
Suppose you are studying a process that has 3 steps all of which must completed in sequence. Suppose step 1 has a DPU of 0.01, step 2 has a DPU of 0.05, and step 3 has a DPU of 0.025. What is the the RTY for the process and what is the DPU for the process?
rty=.9185 dpu=.085
Why do we Straighten when performing 5S (check all that apply) saves time by not needing to search increases travel distance visually identifies what is missing or out of place more efficient to find items
saves time by not needing to search visually identifies what is missing or out of place more efficient to find items
seiso
shine
Which of the following is a type of process map? (check all that apply) sicop map value stream map swim lane map linear flow map
sicop value stream swim lane linear flow
seiri
sort
seiketsu
standardize
Levene's Test of Equal Variance is used to compare the estimated population standard deviation from two or more samples with Non-Normal Distributions. T/F
true
Measurement Error is defined as the effect of all sources of measurement variability that cause an observed value to deviate from the true value. T/F
true
OFAT is inefficient when compared with DOE . T/F
true
Process mapping is a powerful tool you will use to improve the effectiveness and efficiency of a process. T/F
true
Range is typically used for small data sets. T/F
true
Sampling frequency is a balance between the cost of sampling and testing versus the cost of not detecting shifts in mean or variation T/F
true
Six Sigma places emphasis on the process. T/F
true
Six Sigma puts strong emphasis on the customer because they are the ones assessing our performance and they respond by either continuing to purchase our products or services or NOT! T/F
true
Stability is Bias characterized as a function of time T/F
true
Statistics is the basic language of Six Sigma. T/F
true
The 'Null Hypothesis" assumes that there is no differences or relationships and is the default hypothesis of all statistical tests. T/F
true
The 5th stage of 5S is sustaining, to maintain our discipline, we need to practice and repeat until it becomes a way of life. T/F
true
The cause and effect diagram is a tool to generate opinions about possible causes for defects. T/F
true
The components of variation in a measurement system are statistically additive. T/F
true
The first activity of the Measure Phase is to adequately describe the process under investigation. T/F
true
The fourth stage of 5S, Standardizing, involves creating a consistent approach for carrying out tasks and procedures. Orderliness is the core of "Standardization". T/F
true
The goal of the Define Phase is to identify a process to improve and develop a specific lean six sigma project T/F
true
The larger the subgroup size the greater the chance of detecting a special cause. T/F
true
The power of the test is the probability of rejecting the null hypothesis Ho when the alternative hypothesis is true. T/F
true
The primary contributors to measurement system error are repeatability and reproducibility. T/F
true
The primary purpose of linear correlation analysis is to measure the strength of linear association between two variables (X and Y) T/F
true
The vision of lean supporting your project is to achieve and sustain improvements. T/F
true
When dealing with Non-Normal Data, one test the equality of medians instead of the equality of means. T/F
true
While many processes in nature behave according to the Normal Distribution, many processes in business, particularly in the areas of service and transactions do not. T/F
true
X-Sifting is used to determine what the impact of the inputs to the process are on the output T/F
true
An improvement made to the process will detect when an error condition has occurred, setting a flag that shuts down the equipment so the defect does not move forward is known as a __________________________
type 2 corrective action
What type of chart plots defects per unit data collected from subgroups of equal or unequal sizes?
u chart
The Voice of the customer is import to understanding the CTQ's. Which of the following aid in understanding the customer? understand the delivery mechanisms and determine whether the process meets customer time frame understand the customers strengths and weaknesses understand the customers perspective on features understand the customers perceived value vs cost
understand the customers perspective on features understand the customers perceived value vs cost understand the delivery mechanisms and determine whether the process meets customers time frame
The correlation coefficient always takes on a value between ___________ and ____________.
-1 and 1
DPU is a measure of the average number of defects per unit. Suppose you have sampled nine lap top computers, Three of the laptops are defective. One of them has a bad video card, Another one has a bad screen, a bad battery, and a bad camera. A third has 2 bad keys on the keyboard. What is DPU rate for laptops?
.667
A general guideline for practical significance is:If open vertical bar r close vertical bar space greater than space ________, the relationship between X and Y is practically significant
.80
A minimum of X observations is needed to effectively generate a Box plot.
10
As a general rule, long term data consists of
100 to 200 data points over an extended time
The special cause detection rules that are visually the most easily detected are: (check all that apply) 2 out of 3 consecutive points more than 2 standard deviations from the center line 15 points in a row all within 1 stdev of either side of the center line one point more than 3 stdev from center line 6 points in a row all either increasing or decreasing
15 points in a row all within 1 standard deviation of either side of the center line one point more than 3 stdev from center line
A 2^(4-1) fractional factorial experiment, with 2 replications will have how many total runs?
16
A 4-factor full factorial experiment will have how many total runs
16
The standard error approaches zero at about ______________ samples
30
In order for Kanbans to succeed you need each of the following: (check all that apply) ongoing kaizen 5s visual factory standardized work
5s visual factory ongoing kaizen standardized work
The phrase "lean manufacturing" is credited to
James Womac
An appropriate number of distinct categories necessary to estimate process parameters is:
5 or more
An Attribute Gage R&R study requires a minimum of
5 times as many samples as a continuous study
It has been correctly stated that X % of the success of the project is dependent on how well the effort has been defined.
50%
We cannot sustain standardized work without _______________ (check all that apply) 5s kanban visual factory kaizen
5s visual factory
Which of the following statements are correct about 5S (check all that apply) 5s is derived from the Chinese words for five practices leading to a manageable work area 5s is the starting point for implementing improvements to a process 5s means the workplace is clean, there is a place for everything and everything is in its place its strength depends upon the employees and the company being committed to and maintaining it
5s is the starting point for implementing improvements to a process 5s means the workplace is clean, there is a place for everything and everything is in its place its strength depends upon the employees and the company being committed to and maintaining it
How many basic elements of Muda are there?
7
A "3 Sigma" process has a
93% yield
A " 5 sigma process" produces 3.4 PPMO T/F
false
Incorrect data entry, paying the wrong vendor, making a bad product, are all examples of what component of Muda?
Correction
COPQ is a defect not a symptom. T/F
False
Which of the following are measures of precision?
Repeatability and reproducibility
A DOE model is known by theory using concepts of physics, chemistry, biology, etc. and explains relationships outside the area of immediate project needs. T/F
false
Why does Six Sigma have a process focus? A. so we can understand how and why work gets done B. To characterize customer & Supplier relationships C. To Manage for maximum Customer satisfaction while utilizing maximum resources D. To see the process from start to finish as it is currently being performed E. To identify and define defects: Blame the process and the people
a b d
The most desirable approach to Project Selection is:
a structured approach
For a gage used in a study where the variance is between 10-20% and the gage contributes 1-4% is
acceptable
Which of the following is not a characteristic of the normal distribution? All processes exhibit a normal curve shape the distribution is mounded and symmetric the mean divides the area in half for a normal distribution the mean median and mode are the same data point for a normal distribution
all processes exhibit a normal curve shape
The R-squared value estimates the _________________________
amount of variation explained by the model
There are two primary types of data. They are
attribute data and variable data
Which of the following is not a "good" six sigma behavior? avoiding change making data-based decisions embracing change and continuous learning being tenacious, courageous
avoiding change
The components of a business case are: (check all that apply) baseline performance of primary business measure output unit for external customer gap in the baseline performance of the primary business measure from the business objective a primary business measure of output unit for project
baseline performance of primary business measure output unit for external customer gap in the baseline performance of the primary business measure from the business objective a primary business measure of output unit for project
Regression Analysis relies on assumptions about the residuals. The following assumptions about the residuals must be met: (check all that apply) be normally distributed be independent of each other be correlated have a constant variance
be normally distributed be independent of each other have a constant variance
The higher the "sigma level" of a process the .....
better the process
Which of the following are reasons for Multiple modes in your data? catastrophic failures mixtures of distributions dependence independence
catastrophic failure mixtures of distributions dependence
For each of the X's identified in your cause and effect diagram you should classify them as follows: (check all that apply) controllable environment noise equipment procedural
controllable noise procedural
Which of the following are examples of COPQ Soft savings? customer loyalty labor savings scrap reduction missed opportunities
customer loyalty missed opportunities
Which of the following are the classical sources of variation? (check all that apply) cyclical positional static temporal
cyclical positional temporal
A customer service group is interested in estimating the Capability of their call center. A total of 10,000 calls came in during the month but 1500 dropped before they were answered (caller hung up). Find the DPU and Cpk for the process.
dpu = .15 cpk= .845
The goal of lean controls is to sustain your project by _____________________ Muda
eliminating
When you find that two inputs have a large impact on the output Y, but do not have an effect on Y by themselves, then this is called a __________________
interaction
The philosophy of continual improvement, that every process can and should be continually evaluated and improved in terms of time required, resources used, resultant quality and other aspects relevant to the process is know as:
kaizen
__________ is defined as the difference in bias value throughout the measurement range in which the gage (instrument) is intended to be used.
linearity
The following are measure location (check all that apply) range variance mean mode
mean mode
In general, which measure of location is the mid-point or 50th percentile of the data?
median
The following questions are examples of what type of product category? How is this performed? Are Procedures correct? What might be unusual?
method
If a process is both incapable and not centered, then you must:
minimize and get control of the variation first
Extra steps, extra data entry, and having to look for something are examples of what component of Muda
motion
Our goal in Six Sigma is to improve our process capability. We can do this by doing each of the following: (check all that apply) move the process mean reduce the process variation reduce the process mean and reduce the stdev move the process mean and reduce process variation
move the process mean reduce the process variation move the process mean and reduce the process variation
What type of chart shows the individual data points that are represented in a Box plot?
multi-vari chart
Suppose you have non-normal data and the variances are found to be unequal. The unequal variances are usually the result of (check all that apply) multiple modes extreme tails outliers large sample size
multiple modes extreme tails outliers
Which of the following is not a reason for creating a process map? my boss said so it can help understand where problems occur and what some causes may be it can be used as an aid in training it will show you where you can take measurements that will help you to run the process better
my boss said so
The correlation is ______________ when Y tends to decreases with an increase in X and ____________ when Y tends to increase with and increase in X
negative, positive
__________________ occurs when the X and Y scales are different for a given change in X
non-linear realtionship
Which of the following can be used to assess the normality of a data set? (check all that apply) time series plot box plot normal prob test anderson-darling test
norm prob test anderson-darling test
Short term data is characterized by these types of conditions: (check all that apply) many employees many suppliers one batch one shift
one batch one shift
Which of the following are types of cost impacts? direct costs indirect costs one off sustainable
one off sustainable
Which of the following are examples of discrete data? (check all that apply) The number of defective needles in boxes of 200 diabetic syringes the number of surveys returned out of 500 mailed the body temperature for a hospital patient the length of prison time served for individuals convicted of first degree murder
the number of defective needles in boxes of 200 diabetic syringes the number of surveys returned out of 500 mailed
A "3 Sigma" process has a higher COPQ than a "5 sigma" process T/F
true
A Process baseline implies long term performance. T/F
true
A designed experiment can be used to establish a true cause and effect relationship T/F
true
A project COPQ represents the financial opportunity to your teams improvement effort (VOB). T/F
true
A swim lane chart is a cross-functional high level process map where the lines drawn horizontally across the map represent different departments in the company. T/F
true
Although brainstorming can be very structured, it falls far short of being a systematic means of identifying projects that will reduce the COPQ throughout the organization. T/F
true
An experiment is performed in which 17 Golf Club Drivers produced by a particular manufacturer were selected at random and their coefficient of restitution measured. Suppose the mean of the sample is 0.8375, and the Standard deviation is 0.025. Suppose a normal probability plot confirms that the data is normal. Given the following Hypothesis: Ho: Mean =0.82 Ha: Mean > 0.82 Alpha =0.5 Given the data provided, you would reject the null hypothesis and conclude the mean is greater than 0.82 T/F
true
Attribute data is always long term in the shifted condition since it requires so many samples to get a good estimate with reasonable confidence. T/F
true
Before you invest a lot of time analyzing data you must ensure that data has integrity. T/F
true
Brainstorming techniques work because the knowledge and ideas of two or more persons is always greater than that of one individual T/F
true
Business measures are a function of processes. Processes are usually made up of a series of activities. T/F
true
Capability analysis compares the voice of the process to the voice customer. T/F
true
Control charts indicate when a process is "out of control" but not why. T/F
true
FMEA's help you manage risk for your process T/F
true
Five items made at the same time on different machines are not a rational subgroup. T/F
true
For short term data, you are "controlling" all the controllable sources of variation T/F
true
For some input variables, your team may choose to not control them because you think the cost does not justify it? T/F
true
For the normal distribution, the mean equals the mode and the median. T/F
true
I and MR charts are used when each measurement represents 1 batch. The subgroup size for an I-MR chart is equal to one. T/F
true
If all operators have the same repeatability and it is too big the gage needs to be repaired or replaced T/F
true
If the P-value for your regression model is > 0.05, then you fail to reject the Null Hypothesis Ho: Regression equation is not significant. T/F
true
If your input is Normally distributed about a mean then the output Y may not be Normally distributed T/F
true
In any process improvement endeavor, the ultimate objective is to make the process better, faster, and cheaper. T/F
true
The Six Sigma Problem Solving Methodology focuses on: (check all that apply) understanding the relationship between independent variables and the dependent variable monitoring the optimized independent variable identifying the vital few independent variables that effect the dependent variable optimizing the dependent variables so as to control the independent variable
understanding the relationship between independent variables and the dependent variable identifying the vital few independent variables that effect the dependent variable monitoring the optimized independent variable
Brainstorming falls short of being a systematic means of identifying projects that will reduce COPQ throughout the organization because: (choose all that apply) does not include everyone's thoughts and ideas does not fall short of being systematic means of identifying projects that reduce COPQ usually does not utilize a data based approach, relies on tribal knowledge does not ensure we are dealing with the most important high-impact problems but rather what happens to be the recent firefight initiative
usually does not utilize a data based approach, relies on tribal knowledge does not ensure we are dealing with the most important high-impact problems but rather what happens to be the recent firefight initiative
Select those items that make up the value categories in a high level process map
value added, non value added, value enabling
What type of process map is a specialized map that helps you to understand numerous performance metrics associated primarily with the speed of the process?
value stream map
Process capability measures provide insight as to whether the process has a : (Check all that apply) variation issue centering issue run issue inappropriate specification limits a combination of centering and variation issue
variation issue centering issue inappropriate specification limits a combination of centering and variation issue
The three views of a process are: (check all that apply) what it used to be what you think it is what it should be what it actually is
what you think it is what it should be what it actually is
What type of chart plots the average value of each of a number of small sampled sub groups?
x-bar