Six Sigma and Lean Principles

The "Belt" level indicates the level of proficiency and the roles and responsibilities for individuals assigned to Lean Six Sigma projects.

True

The Analyze phase of Six Sigma DMAIC relies heavily on statistical analysis.

True

The Lean Manufacturing methodology starts with the establishment of value for a process.

True

The Value Stream Map is key element of the Lean Manufacturing process.

True

The higher the process sigma, the less variation there is in the process.

True

The problem definition for a Six Sigma project is not completed until the second phase of the DMAIC.

True

The problem solution is created and implemented in the final two phases of the Six Sigma DMAIC.

True

When Lean Manufacturing identifies non value-added steps, it seeks to eliminate or combine them to reduce non value-added effort.

True

What is Movement Waste

Unnecessary movement of employees

What is Transport Waste

Unnecessary transport of a product or goods

What does USL stand for

Upper Specification Limit

Lean 5 Principles

Value, Value Stream, Flow, Pull, Perfection

What metric is the below scenario trying to find: A team was working on improving the process for placing purchase orders. The team was currently in the Improve phase and they were redesigning the five longest steps by first determining if that step needed to be done and if so, what was the easiest way to do it.

Value-Added Time

What does the Lean Six Sigma Tollgate Meeting Template consist of

-Quick review of Project Charter (goals and constraints) -Summary of results from the previously completed project phase -Presentation of technical artifacts from the completed phase -Present a high-level plan for the upcoming phase -Ask for the decision to proceed or go back

What would be considered a Project Risk

-Regulatory -Organizational Culture -Business Disruption

What metrics make up the Customer category of Lean Six Sigma project metrics

-Retention -Receivables turns -Complaints

What metrics make up the Logistics category of Lean Six Sigma project metrics

-Shipping cost -Damage cost -Shipping cycle time

What are the 3 main Six Sigma Metrics used in Lean Six Sigma

-Sigma -DPU (Defects per Unit) -DPMO (Defects per Million Opportunities)

What is the 5 S's stand for in 5S

-Sort -Straighten -Shine -Standardize -Sustain

What is included in a Project Charter

-Summarizes project goals -Clarifies solution scope/deliverables -Documents high-level time and resources constraint -Highlights major risk areas -Template guides the completion

What is a part of the Project Team

-Team Lead -Team Members

What are the 7 categories of waste (TIM WOOD)

-Transport -Inventory -Movement -Waiting -Over Production -Over Production -Defects

What is a part of the Problem Statement and Goal

-What is wrong -Impact -Goal

What metrics make up the Quality category of Lean Six Sigma project metrics

-Yield -Defects -C(pk) -Returns -Rework/Repair

What would The design of the product or service that the process provides be in Y = F (x)

F

What would The normal performance of the equipment that is used within the process be in Y = F (x)

F

What would The testing or inspection that is conducted on the product or service that the process provides be in Y = F (x)

F

What would the procedures explaining what the process operator is supposed to do be in Y = F (x)

F

What metric is the below scenario trying to find: The team was working with a customer service process. They were in the Measure phase and one of the items they were looking at was whether the initial diagnosis of the problem was correct or if the service representative had to try several things to fix the problem.

FTY (First Time Yield)

The business impact from managing a process well is experienced at a future time.

False - Process is IMMEDIATE - PROJECT is a future time

The major risk to successful project completion is whether the project can manage variation and waste in the project activities.

False - Project major risk is UNIQUENESS - PROCESS major risk is manage variation and waste

The objective when managing a process is to create a new capability.

False - the objective of managing a PROJECT is to create a new capability - the objective of managing a process is PREDICABLE EXCELLENCE

A Lean Six Sigma Black Belt is never assigned to lead more than one project at a time.

False - Black belt can manage multiple projects at a time

Design is one of the five phases of Six Sigma DMAIC.

False - D stands for Define

The Lean Six Sigma approach is a principle based problem solving methodology, not a data based methodology.

False - Data driven analysis

Six Sigma methodology was created and introduced to industry by the American Society for Quality (ASQ).

False - Developed by Motorola to improve quality of manufactured products

Projects and processes are managed the same way with similar goals and measurements.

False - Each project and process has SPECIFIC goals and measurements

Yellow Belts often serve as Lean Six Sigma project leaders.

False - Green and Black belts serve as Lean Six Sigma Leaders

Inspect is one of the five phases of Six Sigma DMAIC.

False - I Stands for Improve

Lean Six Sigma projects use the Six Sigma method for customer needs identification (CTQ) and the Lean Manufacturing method for controlling the improvement (Kanban).

False - Lean uses Attributes of Value

A Green Belt position is normally a full-time Lean Six Sigma job.

False - Part-time

A Master Black Belt decides what Lean Six Sigma projects should be initiated.

False - Stakeholders

A Lean Six Sigma project leader is not responsible for planning or tracking cost and schedule.

False - Stakeholders/Managers

The reason Lean and Six Sigma can be combined is because they are analyzing the same data in the same way, just using different terminology.

False - both seek to improve process performance

The first step in a Lean Six Sigma project is to either choose to do a Lean analysis or a Six sigma analysis.

False - both start with customer value proposition

The Lean Manufacturing approach was developed by Henry Ford and introduced by him into his manufacturing facilities.

False - developed by Toyota

A Lean Six Sigma project leader performs all of the project tasks on a typical process improvement project

False - manages team

Lean Manufacturing is a graphical analysis technique and uses no data.

False - process analysis technique that uses data

The Lean Manufacturing methodology seeks to eliminate value-added effort from the process.

False - seeks to eliminate non value added steps

The Lean Manufacturing methodology seeks to improve the process by eliminating process flow.

False - seeks to eliminate waste

Lean Six Sigma uses statistical measures instead of process measures.

False - uses both

What is the Lean Performance metric FTY represent

First Time Yield is the probability that a given unit can successfully pass through a process step without rework or repair

What is the formal definition of CTQ

Formally - an attribute of a part, assembly, sub-assembly, product, or process that is literally critical to quality or more precisely, has a direct and significant impact on its actual or perceived quality

Lean Six Sigma project management is focused on

Goal and activities, not meeting a schedule date or budget number

Who is a knowledgeable practitioner of Lean Six Sigma process and tools

Green Belt

Who is a part-time team leader of Lean Six Sigma improvement projects

Green Belt

What are the 3 types of project management meetings held during a Lean Six Sigma Project

Information Meeting, Problem Solving Meeting, Tollgate/Decision Meeting

Gather process data is a part of which Lean Six Sigma phase(s)

Measure, Improve, Control

What is the Measurement of a Process vs Project

Process - Variances from CTQ, Unit Cost, Unit Time Cycle Project - Specification Compliance, Total Cost, Project Schedule

What is the Risk of a Process vs Project

Process - Variation, Wasted Project - Uniqueness

What is Over-Production Waste

Production ahead of demand

Which CTQ is based on applying Lean Six Sigma methodology

Project CTQ

Large Lean Six Sigma projects require

Project Charter and justification

Lean Six Sigma is applied in what manner

Project based methodology

What does Sustain mean in 5S

Self-discipline until it becomes a habit - reinforced with training and audits

What does Sort mean in 5S

Separating items into proper categories

One reason why Lean and Six Sigma work well together is that they both start with determining the customer value proposition with respect to the problem.

True

Process sigma measures indicate the probability of whether a process output is capable of meeting customer expectations.

True

Process staffing is normally permanent and stable.

True

Process time measurements are focused on unit cycle time.

True

Processes are managed to achieve unit cost targets whereas projects are managed to achieve total cost targets.

True

Processes have a defined starting step and ending step.

True

Processes with smooth, straight-line flow are easier to manage than those with tangled flow.

True

Project charter is a part of which Lean Six Sigma phase(s)

Define

Project customer and stakeholders is a part of which Lean Six Sigma phase(s)

Define

Project team members is a part of which Lean Six Sigma phase(s)

Define

Lean Six Sigma uses the DMAIC approach for project planning.

True

Measure is one of the five phases of Six Sigma DMAIC.

True

What is normally included in a Lean Six Sigma project charter template

-Problem Statement and Goal -High level CTQs -Business Case -Project Scope -Project Milestones -Project Team

What sentence template is used to help write a CTQ

"The product/process function" performs "the customer need" in this "measurable manner"

What metrics make up the Cost category of Lean Six Sigma project metrics

-Product Cost -Support Cost -Scrap cost

What metrics make up the Operations category of Lean Six Sigma project metrics

-Productivity -Safety Incidents -QA audit findings

What would be considered a Project Benefit

-Cost Savings -Increased Revenue

What are the types of CTQs

-Customer CTQ -Operational CTQ -Project CTQ

What is a part of the High Level CTQs

-Customer CTQs -Business CTQs

What are the 4 main Lean Performance Metrics used in Lean Six Sigma

-Cycle Time -Value Added Time -FTY (First Time Yield)

What is a part of Project Milestones

-Define Phase Schedule -Measure Phase Schedule -Analyze Phase Schedule -Improve Phase Schedule -Control Phase Schedule

What is the primary uses of a Project Charter

-Document project approval -Communicate project expectations to stakeholders -Focus project team during the life of the project

What is a part of the Business Case

-Explain why this cause is worth doing -Cost -Benefits -Risks Associated with Project -Risks if project is not implemented

What is the point of discovering a projects Y = F (x)

-Explains how the process inputs and outputs interact -Predicts the process output, based upon the inputs and controls provided -To "tune" the process for optimal performance and minimal variation and waste

What is a part of Project Scope

-In Scope -Out of Scope

What kind of meeting would be a Formal, Scheduled Meeting

-Information -Tollgate

What kind of meeting would review work the project team has completed

-Information -Tollgate

What metrics make up the Materials category of Lean Six Sigma project metrics

-Inventory costs -Expedite costs -Inventory turns

What metrics make up the Schedule category of Lean Six Sigma project metrics

-Missed Dates -Fill Rates -Process Time cycle

What was the 3 general categories of waste for Lean Manufacturing created my Toyota

-Muda -Mura -Muri

What metrics make up the Performance category of Lean Six Sigma project metrics

-Output -First pass yield -Field failures -Returns

What metrics make up the Labor category of Lean Six Sigma project metrics

-Overtime -Absenteeism -Grievances

What would be considered a Project Cost

-People -Travel -Training -Capital Equipment

What is the 9 categories of metrics used by Lean Six Sigma projects

-Performance -Quality -Schedule -Cost -Customer -Materials -Labor -Operations -Logistics

What are the characteristics of a Stable Process

-Predictable process performance - avg, min, max -Predictability over time -Levels of predictability can be measured and performance can be tracked

What kind of meeting would result usually in a decision

-Problem Solving -Tollgate

What is the definition of a process

A particular method of doing something, generally involving a number of steps or operations

What kind of meeting can be conducted in face-to-face setting

All 3 - Information, Tollgate, and Problem Solving

What kind of meeting can be conducted virtually

All 3 - Information, Tollgate, and Problem Solving

What kind of meeting would Project stakeholders be in attendance

All 3 - Information, Tollgate, and Problem Solving

What kind of meeting would process of problem subject matter experts be in attendance

All 3 - Information, Tollgate, and Problem Solving

What does the x in fundamental Lean Six Sigma formula represent

All of the process variable inputs and controls. Things the process designers, operators, or supervisor can control and affect

What is the Six Sigma metric DPU represent

Defects per Unit is the average number of observed defects on a unit in production

Create high level process map is a part of which Lean Six Sigma phase(s)

Define

Define magnitude of potential improvement is a part of which Lean Six Sigma phase(s)

Analyze

Determine root cause or causes is a part of which Lean Six Sigma phase(s)

Analyze

Identify sources of variation

Analyze

Identify sources of variation and waste is a part of which Lean Six Sigma phase(s)

Analyze

Set the improvement goal is a part of which Lean Six Sigma phase(s)

Analyze

What Six Sigma phases are apart of Problem Analysis

Analyze

What is the relationship between Y = F (x) and the Analyze Phase

Analyze the data to develop the formula - the "F"

Determine current process performance is a part of which Lean Six Sigma phase(s)

Analyze, Control

Determine Y=f(x) is a part of which Lean Six Sigma phase(s)

Analyze, Improve

What does Straighten mean in 5S

Arrange the work space for easy flow and close proximity to where they are used

When do you submit Project Deliverables

At the end of each phase

Develop project charter is a part of which Lean Six Sigma phase(s)

Define

Identify project goals is a part of which Lean Six Sigma phase(s)

Define

Who is a full time team leader on Lean Six Sigma improvement projects

Black Belt

Who is the subject matter expert on Lean Six Sigma process and tools

Black Belt

Lean Six Sigma uses what attribute values

CTQs

What does Shine mean in 5S

Clean the workspace daily, improving safety and reducing maintenance

What is the relationship between Y = F (x) and the Measure Phase

Collect "x" input and "Y" output data from current process

Close project is a part of which Lean Six Sigma phase(s)

Control

Control plan for the new process is a part of which Lean Six Sigma phase(s)

Control

Ensure organizational change actions are complete is a part of which Lean Six Sigma phase(s)

Control

Implement the control plan is a part of which Lean Six Sigma phase(s)

Control

What is Defect Waste

Correcting defective parts

What is Mura Waste

Creates unevenness or variability in the process flow

What does CTQ stand for

Critical to Quality

Which CTQ is external facing

Customer CTQ

What metric is the below scenario trying to find: The team is in the Measure phase on a manufacturing assembly process and they are evaluating the average amount of time it takes a unit to go from the first step to the last step

Cycle Time

What metric is the below scenario trying to find: The team was working to improve a manufacturing process and they were in the Analyse phase, working with data collected by the automated test equipment. The equipment checked 43 attributes on each product and printed out a report that showed how well the product did against each of the attributes.

DPMO (Defects per Million Opportunities)

What is the primary measurements used in Six Sigma

DPMO or Defects per Million Opportunities and Process capability "Sigma" Level

What metric is the below scenario trying to find: The team is in the Control phase of a project to improve the running of payroll, and they are putting a control plan in place. One of the metrics is based upon determining the number of errors on a person's pay check.

DPU (Defects per Unit)

What is the Six Sigma metric DPMO represent

Defects per Million Opportunities is the average number of observed defects in a production run divided by the total number of opportunities to create a defect in that run, normalized to 1,000,000

What Six Sigma phases are apart of Problem Definition

Define and Measure

What does DMAIC stand for in six sigma?

Define, Measure, Analyze, Improve, Control

Map the process is a part of which Lean Six Sigma phase(s)

Define, Measure, Improve

What is the 5 Six Sigma Principles

Define, Measure. Analyze. Improve, Control

What is the relationship between Y = F (x) and the Define Phase

Determine which "Y" outputs are to be improved or optimized

What is an easy way to Estimate Benefits

Establish a saving rate on a per-unit basis (per month, per hour, etc.)

Visual process control is used so that

Everyone can see how the process is going and where trouble is occurring

What does Standardize mean in 5S

Everything in its right place and everyone following best practice

All processes have tangled flow.

False

What is the informal definition of CTQ

Informally - What the customer cause about most/driver of custom needs

What is Inventory Waste

High inventories greater than necessary

What is the relationship between Y = F (x) and the Control Phase

Implement the redesigned process with control limits for the "x" factors

Develop an improvement strategy is a part of which Lean Six Sigma phase(s)

Improve

Perform a design of experiments study is a part of which Lean Six Sigma phase(s)

Improve

Screen potential problems is a part of which Lean Six Sigma phase(s)

Improve

Test prototype of simulation is a part of which Lean Six Sigma phase(s)

Improve

Test the solution is a part of which Lean Six Sigma phase(s)

Improve

What Six Sigma phases are apart of Problem Solution

Improve and Control

Applying Lean Six Sigma to a process should

Improve quality and decrease cycle time

What is the formula for the Taguchi Loss Function in Lean Six Sigma

Loss = k * (y - m)^2

What does LSL stand for

Lower Specification Limit

Who administers the Lean Six Sigma program

Master Black Belt

Who trains and coaches Black Belts and Green Belts

Master Black Belts

Collect data is a part of which Lean Six Sigma phase(s)

Measure

Create detailed value stream map

Measure

Define performance standards is a part of which Lean Six Sigma phase(s)

Measure

Measurement system analysis is a part of which Lean Six Sigma phase(s)

Measure

Which phase if often the longest during a Lean Six Sigma project

Measure

Establish process capability is a part of which Lean Six Sigma phase(s)

Measure, Control

Validate the measurement system is a part of which Lean Six Sigma phase(s)

Measure, Control

What kind of meeting is focused on lessons learned and improving the Lean Six Sigma methodology

Not a Stakeholder Project Review

Which CTQ is internal facing

Operational CTQ

What is Muri Waste

Overburdening of people or equipment putting stress on the process operation

What is Over-Process Waste

Performing unnecessary steps

What is the logical process for Six Sigma

Problem Definition, Problem Analysis, Problem Solution

What kind of meeting is often conducted in a brainstorming approach

Problem Solving

What kind of meeting would be an Ad hoc meeting scheduled when needed

Problem Solving

What is the Time Period of a Process vs Project

Process - Continuous Project - Limited

What is the Business Impact of a Process vs Project

Process - Immediate Project - Future

What is the Staffing of a Process vs Project

Process - Permanent, Stable Project - Temporary, Variable

What is the Objective of a Process vs Project

Process - Predictable Excellence Project - New Capability

What metric is the below scenario trying to find: The team is in the Define phase of a project to improve the customer ordering experience. One of the targets set by the stakeholders was that 98% of the time, a customer would be able to correctly order a product from the website without any problems or difficulties at any step in the process.

RTY (Rolled Throughput Yield)

What is the relationship between Y = F (x) and the Improve Phase

Redesign the process and determine the optimal settings and tolerances for the "x" inputs

What is the Lean Performance metric RTY represent

Rolled Throughput Yield is the probability that a given unit can pass through all the steps in a process without ever experiencing a defect. That is the product of FTY for each step

What symbol is used for Standard Deviation

Sigma

What metric is the below scenario trying to find: The team is in the Analyze phase of a process for improving the speed of shipping products to customers. As they are analyzing, they find that the time for processing the shipment in their warehouse varies by over 5 hours, but to meet their promises to customers they need to reduce that down to less than 30 minutes.

Simga

Main difference between Lean and Six Sigma

Six Sigma uses statistics to maintain process control while Lean manufacturing is a much more visuals control approach

What does the blue line represent in the Variation Graph

Taguchi Loss Line

Lean Six Sigma Yellow Belt team members are normally product or process subject matter experts.

True

What is the Lean Performance metric Cycle Time represent

The Total amount of time required to move a unit through all the steps in a process including both active working time and delay time

What are Project Deliverables

The final results of the project activities including data and analysis, reports, design documentation, and procedures

What does the F in fundamental Lean Six Sigma formula represent

The function that describes how all the x's give the Y output

Lean Six Sigma follows a structured project management methodology.

True

What does the Y in fundamental Lean Six Sigma formula represent

The output of the process with typical attributes: -Quantity -Performance -Time -Quality/Yield

What is the Six Sigma metric Sigma represent

The standard deviation of a population of data. It is used as a scaling factor to compare process variation against specification limits.

What is the primary challenge that must be overcome when merging the Lean Manufacturing and Six Sigma methodologies?

There are no challenges, the methodologies are complementary

Lean primary measurements are

Throughput and "Value-added" time and activities

What is the Lean Performance metric Value-Added Time represent

Time spent on a process step in which the process resources are directly creating customer value in a unit

What is the main purpose of the Define phase

To clearly and precisely describe the goal of the project and to align the project with the organizational priorities

What is the main purpose of the Measure phase

To collect accurate, meaningful, and reliable data concerning the process/product characteristics that relate to the customer CTQ (Critical to Quality)

What is the main purpose of the Analyze phase

To define how well the process is currently performing and to identify how much it can be improved

What is the main purpose of the Improve phase

To determine how to improve the process

What is the primary objective of a Six Sigma analysis

To eliminate variation

What is the main purpose of the Control phase

To ensure the process improvements and controls are implemented and sustained so that the process achieves the performance goal

What is the purpose of a Business Case

To give stakeholders they need to make a decision on how to best allocate resources

Lean Six Sigma projects strive to eliminate both waste and variation.

True

What is Process Sigma

To measure and indicate the probability of whether a process output is meeting customer specifications

Lean Six Sigma Phase endpoints are often applied as

Toll-gates or phase gate meeting with the stakeholders

What kind of meeting occurs at the end of Lean Six Sigma phase

Tollgate

What kind of meeting typically includes a review of the project charter

Tollgate

A Black Belt is considered to be a Lean Six Sigma subject matter expert.

True

A Black Belt position is normally a full-time Lean Six Sigma job.

True

A Master Black Belt normally administers the Lean Six Sigma initiative within an organization.

True

A Master Black Belt normally provides training and coaching to other "Belts" within the organization.

True

A primary measure of the Lean Manufacturing methodology is process throughput.

True

A process is a series of related actions that are organized to achieve an objective

True

A process time period is considered to be continuous because it is repeated again and again.

True

A successful Lean Six Sigma project will often result in both improved quality and shorter cycle times from the process being improved.

True

Control is one of the five phases of Six Sigma DMAIC.

True

In Lean Manufacturing, visual control is incorporated to ease process management and eliminate waste

True

Lean Manufacturing methodology creates an "As-Is" Value Stream Map so as to understand areas of process waste.

True

What is Waiting Waste

Waiting for the next process step

What is Muda Waste

Wasted effort that does not add value to the product or service that is delivered to the customer

What would The number of units completed by the process in a day be in Y = F (x)

Y

What would The speed of the process be in Y = F (x)

Y

What would the quality of the process output be in Y = F (x)

Y

What is the fundamental Lean Six Sigma formula

Y = f (x)

Who has awareness of Lean Six Sigma and project team memeber

Yellow Belt

What does the y represent in the Taguchi Loss Function

actual performance

What does the k represent in the Taguchi Loss Function

constant representing the units of loss

Lean methodology starts by

mapping "As Is" or current state of the process

CTQs should ____________ to be actionable

measureable

What does the m represent in the Taguchi Loss Function

the target

Smaller Lean Six Sigma project require

usually lumped together in portfolio for manager or stakeholders to decide

What would The information used to setup the process be in Y = F (x)

x

What would The maintenance that is done on the equipment used in the process be in Y = F (x)

x

What would The schedule or signal that tells a process or process operator when to start be in Y = F (x)

x

What would The standard used to set the acceptable quality level for the product or service that the process provides be in Y = F (x)

x

What would the experience of the operator who is running the process be in Y = F (x)

x