Lean Six Sigma Tools

T/F: A R-Sq value of 90% means that 90% of the variation in the observed values CANNOT be explained by the regression equation.

False

T/F: Calibrated equipment will always have repeatable and reproducible measurements.

False

T/F: In an FMEA, if the current controls have little or no likelihood of detecting the failure mode, then the Detection score should be very low.

False

T/F: Multi-voting is useful for determining root causes or key Xs.

False

Which of the following tools proves or disproves a likely X to be a root cause or key X?

hypothesis test

Pull in JIT refers to the pull of...

Customer demand

Six Sigma improvement methodology has the following phases:

Define Measure Analyze Improve Control

What are Warranty and Recalls examples of?

External Failure cost

Pilot testing of solutions are carried out during the...

Improve phase.

Re-do or Rework is an example of...

Internal Failure cost

Plot processing times by using any of the following, EXCEPT:

Pareto chart

When developing the SIPOC diagram, start with the...

Process column.

What is the rate of customer demand called?

Takt rate

Data collection planning in the Measure phase starts with specific questions regarding...

Y

To display the graphical relationship between Y and a likely X, use...

a Scatterplot

The Pugh concept selection method compares each alternative to...

a common baseline option

If the same item is measured by different people, it should have the same result. This is called...

reproducibility

Power of a hypothesis test is determined by...

sample size

Process control plans should NOT address:

what to improve

What is the Rolled Throughput Yield of this 3-step process with yields of 90% each?

72.9% (.9x.9x.9)

When analyzing a value stream map, a large difference between Processing Time and Lead Time of a process block requires a...

"deep dive" analysis of that process block using detailed process maps

What is "Time from order to delivery" an example of?

CTQ metrics or process metric

Tools for the Improve phase include all of the following except ...

Cause-effect diagram

The following are steps in the Measure phase EXCEPT: _____.

Collect data to analyze the problem

To determine which product accounts for the majority of defects, use a ...

Pareto chart

T/F: Criteria for a criteria selection matrix should include Critical to Quality Requirements (CTQs).

True

T/F: Deliverables from the Define Phase include: project charter, SIPOC, stakeholder analysis, communication plan, COPQ to be reduced, project plan with DMAIC milestones.

True

T/F: FMEA can be used to evaluate both current and improved processes.

True

Stratify data by asking all of the following, EXCEPT:

Why

For valid data, all agreements (agreement within appraisers, between appraisers, and with the expert) should be...

at least 90%

The main focus of the Measure phase is to understand and measure the...

baseline performance of Y

What is "I don't like cold pizzas" an example of?

customer need or VOC

In the Analyze Phase, all of the following are done, except for...

develop solutions to improve Y

T/F: Cause-effect diagrams determine the root causes.

false

Collecting the VOC of internal customers in a LSS project is most effective when using...

focused groups of customers of the process organized as VOC Workouts/Kaizen events

Scoring in a criteria selection matrix...

is Relative

Elapsed time an item spends moving through a process from start to finish is called...

lead time

When a process is out of control, there is ___ variation due to ____ causes

non-random; special

To map a cross-functional process, the best type of map to use is a...

swimlane process map

In an FMEA, the Severity score is for scoring...

the Effect

The line in the box of a boxplot shows...

the median

What does a correlation coefficient of 0.9 mean?

there is a strong positive relationship between two variables

What is the null hypothesis for correlation?

there is no significant correlation

If Cpk = 1, the process is performing at a ____ sigma level.

three

If throughput rate is less than Takt rate, we have...

waiting and delays

An example of a common cause is...

poor workstation design

T/F: Participation in Kaizen events is limited to the project team.

False

T/F: Planning for data collection in the Analyze phase is unnecessary if a data collection plan was developed in the Measure phase.

False

What should the effect on a cause-effect diagram be based on?

Pareto chart dotplot OR boxplot

T/F: COPQ consists of Prevention, Appraisal, Internal Failure and External Failure costs.

False, COPQ excludes prevention costs

T/F: The SIPOC diagram is an excellent mapping tool for analyzing the process.

False, it is not detailed enough for analysis

T/F: Cp is always less than Cpk

False, it's always greater than or equal to

T/F:Training and Design Reviews are part of COPQ

False, they are prevention costs

Which graph is appropriate for plotting and analyzing number of defects found at different locations?

Pareto charts

Which of the following graphs would NOT be appropriate for plotting and analyzing transaction processing times of multiple work teams?

Pareto charts

A key deliverable of the Control phase is:

Process control plan

In 6S, the sixth S is...

Safety

What is the correct sequence of 5S?

Sort Straighten Sweep Standardize Sustain

T/F: For effective value stream management, authority should be commensurate with responsibility and accountability.

True

T/F: Hypothesis testing is set up as a pair of statements - a null hypothesis and an alternative hypothesis.

True

T/F: If Takt time is 30 seconds, then Takt rate is two per minute.

True

T/F: If error-proofing by prevention is not possible, then apply error-proofing by facilitation and detection to minimize errors.

True

T/F: Multi-voting on a cause-effect diagram is useful for narrowing the list of likely causes.

True

T/F: Process capability is a measure of how well the process meets specifications.

True

T/F: The Project Charter must state the Key Metric to be improved. The Key Metric is the Y in Y=f(x) for the project.

True

T/F: When analyzing a value stream map, identify and target process blocks with low Yields or large differences between Processing Time and Lead Time for further analysis.

True

T/F: When mapping a process, start with a high-level process map first.

True

T/F: Work in Process or WIP are the all items being processed and waiting to be processed.

True

T/F: The Pugh concept selection method has scores of 1 to 10 to evaluate each alternative against a common set of criteria.

False

T/F: a process in statistical control is always capable of meeting specifications

False

T/F: specification limits are placed on a SPC chart at plus/minus 3 standard deviations from the mean

False

Benefits of just-in-time flow and pull, instead of push, include all of the following except...

better product design

If process spread is less than specifications width, then the process is ...

capable

The Goal of a LSS Project should NOT be...

comprehensive It should be specific so as to focus the project team's efforts

A Kaizen event may have any of the following objectives except...

conduct statistical data analysis

If there are outliers in a set of data, the most appropriate measure of central tendency is...

median

Making it impossible to complete a task incorrectly is an example of error-proofing by...

prevention

What does the Project Charter consist of?

problem and goal statements project scope Expected benefits project team and stakeholders milestones and approval signatures

Tools that enable effective value stream management on a daily basis include the following except....

project charters, which are for projects and not for managing a process or value stream

Control subjects in a process control plan should NOT include:

projects

To map the overall end-to-end process activities, performance, material and information flows, use a...

value stream map