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
