Lean Six Sigma Green Belt - Week 1: Introduction to LSS

A change in a process in the milling department will NOT have an effect on the assembly area. True False

False

A revamped health care system would have equal impact on both the health care industry and the automotive industry. True False

False

Company XYZ allows each department to create their own metrics with no requirement for feedback loops or linkages between departments. This is an example of an effective system. True False

False

Company XYZ requires 100 % inspection prior to shipping, and this process is considered to be a value-added activity. True False

False

Deming is most widely recognized for developing the Ishikawa diagram (cause and effect diagram), which is often referred to as the fishbone. True False

False

Increases in inflation would be an example of a controllable organizational driver. True False

False

James Womack founded the Lean Enterprise Academy in the United Kingdom. True False

False

Ownership of the milling department's metrics resides in the quality department. This is an example of assigning ownership with the party held accountable. True False

False

Painting a part that does not require painting is an example of a value-added activity. True False

False

Part of your process includes a checking and reviewing step is considered a value-added activity. True False

False

____________ was responsible for providing a wake-up call to the world about the capabilities of the Lean Production system that Toyota was using and how good it was. a) W. Edwards Deming b) James Womack and Daniel Jones c) Malcolm Baldrige d) Joseph Juran

James Womack and Daniel Jones

___________ was responsible for the creation of The Quality Control Handbook? a) Malcolm Baldrige b) Philip Crosby c) Joseph Juran d) Frederick Winslow Taylor

Joseph Juran

A mandatory government overcheck that is unnecessary to build and deliver the product is an example of a required non-value added activity. True False

True

A non-value added activity is also known as waste. True False

True

A value-added vs. non-value-added analysis is a method of looking at process steps from the customer's perspective. True False

True

During your conversations with customers, you learn the customer starts calculating the process cycle time as soon as they begin to interact with a process, which is the common interpretation by the customer. True False

True

Eiji Toyoda become President of Toyota Motor Company. True False

True

Henry Ford helped build a factory that included vertical integration of raw materials. True False

True

In 1911 Taylor published a book titled The Principles of Scientific Management. True False

True

One of Crosby's Four Absolutes of Quality is that the performance standard is zero defects. True False

True

One of the aims of the Lean methodology is to reduce cycle time. True False

True

The addition of the assembly line reduced construction of a chassis from 12 hours to less than two hours. True False

True

The phrase "to effect real change, we must focus on the Xs" means that, in order to solve problems, we need to work on the inputs or causes (independent variables). The Ys or symptoms are the effect of the process and can only be monitored but not controlled. True False

True

The work Armand Feigenbaum did at General Electric was the basis for his ideas on total quality control. True False

True

Two essential components of a successful balanced scorecard are making the scorecard visible and communicating progress. True False

True

Value is what the customer is willing to pay for a specific product with specific capabilities at a specific price and at a specific time. True False

True

Waiting for signatures to proceed is an example of required non-value-added activities. True False

True

Walter Shewhart is responsible for creating process quality control and the control chart. True False

True

You are preparing to develop a performance metric. You should involve the employees who are responsible for the work to be measured. True False

True

Your team is assigned the development of a new product. The correct methodology for this problem is Design for Six Sigma (DFSS). True False

True

ou are preparing to launch an improvement project. Which of the following focuses on improving existing processes? a) DMAIC b) DFSS c) DMADV d) none of the above

a) DMAIC

Which of the following is NOT one of Philip Crosby's Four Absolutes of Quality? a)Quality is everybody's job. b)Quality is conformance to requirements. c)The system of quality is prevention. d)The performance standard is zero defects. e)The measurement of quality is the price of non-conformance.

a) Quality is everybody's job

You are planning a meeting to identify value from the customer's perspective. Which of the following tools are you likely to use? a) VOC tree, CTQ tree, and SIPOC b) Kaizen and Blitz c) Improve and Control d) DOE, MSA, and FMEA

a) VOC tree, CTQ tree, and SIPOC

You are gathering customer requirements from a focus group meeting. Which phase of the DMAIC process are you in? a) define b) measure c) analyze d) improve e) control

a) define

Womack laid out five guiding principles for Lean. Which of the following is one of the five principles? a) Pursue to perfection. b) Voice of the customer comes first. c) Return on investment is critical. d) Value must be designed by the producer. e) all of the above

a) pursue to perfection

Muda is a Japanese word that means ________. a) waste b) work c) poka-yoke d) sensei

a) waste

Which of the following is NOT one of the seven categories of the Malcolm Baldrige National Quality Award Criteria? a)results b)statistical quality control c)customer and market focus d)strategic planning

b) Statistical Quality Control

The definition of a process is _____________________________. a) a series of steps that should never be changed b) a collection of related, structured activities that produce a product or service that meets the customer's needs and requirements c) documentation required for ISO certification d) the rules that must be followed by all individuals in the organization

b) a collection of related, structured activities that produce a product or service that meets the customer's needs and requirements

If a process has reached Six Sigma level, how many defects does it produce? a) none b) 5% c) 3.4 DPMO d) it is difficult to say because variation is not controllable

c) 3.4 DPMO

Your company is faced with shrinking order quantiles and high setup times. Your plan of attack is to reduce the length of setup time. ___________ is credited with this concept. a) Genichi Taguchi b) W. Edwards Deming c) Shigeo Shingo d) Kaoru Ishikawa

c) Shiego Shingo

What does the acronym DMADV stand for? a) define, measure, act, design, vet b) define, measure, analyze, design, validate c) define, measure, analyze, design, verify d) none of the above

c) define, measure, analyze, design, verify

Lean Six Sigma is different from other methodologies because it focuses on _____________. a) training employees in statistics b) team-based results c) financial results d) waste

c) financial results

Womack laid out five guiding principles for Lean. Which of the following is one of those five principles? a) just-in-time manufacturing b) PDCA cycle c) make value flow d) drive kaizen events throughout the organization

c) make value flow

Which of the following processes are the focus areas of Taguchi's design phase? a) system design: the process of applying scientific and engineering knowledge to produce a basic functional prototype design b) parameter design: the investigation conducted to identify settings that minimize (or reduce) the performance variation c) tolerance design: the method for determining tolerances that minimize the sum of product manufacturing and lifetime costs d) all of the above

d) All of the Above

Who is recognized as the father of Total Quality Management? a) Genichi Taguchi b) W. Edwards Deming c) Joseph Juran d) Armand Feigenbaum

d) Armand Feigenbaum

Who is responsible for the creation of the seven basic quality tools and, specifically, the fishbone diagram? He also believed these tools should be taught to everyone in the organization. a) Genichi Taguchi b) W. Edwards Deming c) Joseph Juran d) Kaoru Ishikawa

d) Kaoru Ishikawa

The father of the Toyota Production System and the Seven Types of Waste was ______________. a) Henry Ford b) W. Edwards Deming c) Malcolm Baldrige d) Taiichi Ohno

d) Taiichi Ohno

Who is responsible for creating process quality control and the control chart? a) Dr. W. Edwards Deming b) Dr. Joseph Juran c) Henry Ford d) Walter Shewhart

d) Walter Shewhart

____________ framed the problem of variation in terms of assignable-cause and chance-cause variation. Question options: a) Henry Ford b) Frederick Winslow Taylor c) W. Edwards Deming d) Walter Shewhart

d) Walter Shewhart

In your Green Belt project you found that pressure impacts the diameter of the part. In this case, what does the pressure represent in the project? a) DPO b) DPMO c) CTQ d) X Variable

d) X Variable

In which industries do the lean tools apply? a) healthcare (maintain the flow of patients through the process) b) financial (error-proof online banking systems) c) food service (quick changeover from breakfast to lunch menus) d) all of the above

d) all of the above

Six Sigma is a _______________________. a) measure of performance b) leadership development program c) culture and mindset d) all of the above

d) all of the above

What are the obstacles addressed in the book The Machine that Changed the World? a) the existing stronghold of mass production on existing companies b) outdated thinking about the world economy and globalization c) inward focus and selective implementation of the methodology d) all the above

d) all the above

Company XYZ developed a comprehensive balanced scorecard. Since implementing the balanced scorecard, there has been very little improvement. The possible reason may include ____________________. a) failing to make the scorecard visible b) no balanced scorecard was available through a visual management board c) no communication of progress d) both a and c

d) both a and c

ou are preparing to run a pilot for new machine settings. Which phase of the DMAIC process are you in? a) define b) measure c) analyze d) improve e) control

d) improve

You are trying to reduce the variation in the diameter of the part in your area and improve the Cpk from its current .5 value. The diameter of the part is the______________. a) variable to investigate b) root cause c) CTQ d) output of a process

d) output of a process

When is the best time to deploy DFSS? a) along with the DMAIC deployment b) immediately after the DMAIC deployment c) when the vice president of development states that the department is ready d) when it appears the organization has met many of the readiness criteria/signs

d) when it appears the organization has met many of the readiness criteria/signs

Which of the following are included in W. Edwards Deming's 14 points for management. a) create constancy of purpose toward improvement of products and services b) adopt the new philosophy c) cease dependence on inspection to achieve quality d) end the practice of awarding business on the basis of price tag; instead, minimize total cost e) all the above

e) All of the Above

Which of the following is an example of MUDA? a) mistakes that require fixing b) extra processing steps that are not needed c) idle employees waiting on material from upstream processes d) a and b e) a, b, and c

e) a, b, and c

A balanced scorecard would include _________. a) financial measures b) internal business process measures c) learning and growth measures d) customer measures e) all of the above

e) all of the above

Lean is about _______________________. a) providing customer value b) respecting people c) keeping things moving d) taking a long-term view e) all of the above

e) all of the above

The DMAIC methodology includes which of the following steps? a) define the process b) evaluate risks on process inputs c) identify waste d) finalize the control system e) all of the above

e) all of the above

Which of the following are included in W. Edwards Deming's 14 points for management. Question options: a) create constancy of purpose toward improvement of products and services b) adopt the new philosophy c) cease dependence on inspection to achieve quality d) end the practice of awarding business on the basis of price tag; instead, minimize total cost e) all the above

e) all of the above

ou are preparing for a team meeting that will determine the non-value-added activities. Which of the following questions should you ask the team to determine if a step is adding value? a) Does the step transform the item going through it? b) Would the customer be willing to pay for that step to be done? c) Was this step done right the first time? d) both a and c e) all the above

e) all the above

What are two major supporting subsystems of the Lean methodology? a) just-in-time (JIT) b) Jidoka c) SMED d) theory of constraints e) both a and b

e) both a and b

The most critical process in Company XYZ is the milling process. While they have created measures to monitor the process, they continue to struggle to improve. Which of the following is the most likely reason for no improvement. a) No standard was set. b) The measure is correlated with the milling process. c) The metric is reviewed daily. d) The metric is reviewed at the end of the quarter. e) both a and d

e) both a and d