Yellow belt 6 sigma
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 common themes from the early process improvement methodologies are customer focus, process focus, team-based, and data based.
True
The higher the process sigma, the less variation there is in the process.
True
When Lean Manufacturing identifies non value-added steps, it seeks to eliminate or combine them to reduce non value-added effort.
True
Time spent on a process in which the process resources are directly creating customer value in a unit.
Value - added time
What is value stream mapping?
Value stream mapping (VSM) is defined as a lean tool that employs a flowchart documenting every step in the process. Many lean practitioners see VSM as a fundamental tool to identify waste, reduce process cycle times, and implement process improvement.
What data is measured data along some scale?
Variable data
An individual or department within the performing organization that receives or uses an output from the process being studied
internal customer
Complaints, repairs, warranties, sales reductions, bad will, and environmental compliance problems are examples of
External cost
What acronym is FMEA?
Failure Modes and Effect Analysis.
The Lean Manufacturing methodology seeks to eliminate value-added effort from the process.
False
The Lean Manufacturing methodology seeks to improve the process by eliminating process flow.
False
The Lean Six Sigma approach is a principle based problem solving methodology, not a data based methodology.
False
The Six Sigma process methodology was created at the General Electric company.
False
The business impact from managing a process well is experienced at a future time.
False
The first step in a Lean Six Sigma project is to either choose to do a Lean analysis or a Six sigma analysis.
False
The major risk to successful project completion is whether the project can manage variation and waste in the project activities
False
The objective when managing a process is to create a new capability
False
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
Yellow Belts often serve as Lean Six Sigma project leaders.
False
Scrap, rework downtime, delays, shortages, and failures are example of
Internal costs
The material in this program aligns with the Body of Knowledge from which international testing and certification agency?
International Association of Six Sigma Certification (IASSC)
Which of these are included in the IASSC Yellow Belt Body of Knowledge as part of the Measure Phase?
Measurement Systems Analysis
Any activity without value, Those activities that consume resources but do not add any value to the customer.
Muda
Inconsistency in the content and flow of work that is caused by changes in volume (uneven demand), mix (different work content), and quality (rework).
Mura
Unnecessary tasks, Placing unrealistic workloads on people and equipment, which leads to stress, mistakes, rework, poor morale, and eventually burnout.
Muri
Technique for describing the process and providing a framework for collecting process data.
Process mapping
What is a typical measure of process variation on Lean Six Sigma projects?
Process sigma
Which set of items is normally included in a Lean Six Sigma project charter?
Scope, Schedule, and Resources
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
Professor Walter Shewhart and Joseph Juan were early leaders in the quality process improvement efforts.
True
How does 6 sigma help with decision making?
organizations can identify problems, validate assumptions, brainstorm solutions, and plan for implementation to avoid unintended consequences. By applying tools such as statistical analysis and process mapping to problems and solutions, teams can visualize and predict outcomes with a high-level of accuracy, letting leadership make decisions with less financial risk.
A list of topics and tools that a lean 6 Sigma yellow belt practitioner should level know.
the IASSC Yellow Belt Body of Knowledge?
What do 6 sigma reduce
the Six Sigma method ultimately reduces process costs and increases customer satisfaction.
The Lean Manufacturing approach was developed by Henry Ford and introduced by him into his manufacturing facilities.
False
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
Under what conditions would you likely experience no variation in the output of a process?
There is no condition where this will occur. All processes create variation at all times - just the level of variation changes
Why are Lean Six Sigma projects always focused on improving manufacturing processes?
They are not - any business process can be the focus of improvement
Attribute data can take an infinite number of values
false
The processes and procedures in the business that are used to resolve quality problems. They are major elements in the COPQ
hidden factory
The problem definition for a Six Sigma project is not completed until the second phase of the DMAIC.
true
Variable data can take on an infinite number of values
true
In Lean Six Sigma projects, what does the "x" in the Y=F(x) formula represent?
x" represents the set of process inputs and controls
In what project phase do you Identify project goals.
Define
What project phase does the project deliverable does, project charter
Define
A Lean Six Sigma Black Belt is never assigned to lead more than one project at a time.
False
A Lean Six Sigma project leader is not responsible for planning or tracking cost and schedule.
False
A Lean Six Sigma project leader performs all of the project tasks on a typical process improvement project.
False
All processes have tangled flow
False
Design is one of the five phases of Six Sigma DMAIC.
False
Inspect is one of the five phases of Six Sigma DMAIC.
False
Lean Manufacturing developed the concept of Yellow Belts, Green Belts, and Black Belts.
False
Lean Manufacturing is a graphical analysis technique and uses no data.
False
What project phase does the project deliverable does, Create detailed Value Stream Map
Measure
What project phase does the project deliverable does, Measurement System Analysis
Measure
In what project phase do you Validate the measurement system.
Measure Control
In what project phase do you Gather Process Data.
Measure Improve Control
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
Processes have a defined starting step and ending step
True
Lean and Six Sigma are focused on internal improvements and therefore the external customer is not a major aspect of the methodology.
False
Processes with smooth, straight-line flow are easier to manage than those with tingled flow.
True
Projects and processes are managed the same way with similar goals and measurements.
False
In Lean Six Sigma projects, what does the "Y" in the Y=F(x) formula represent?
"Y" is the process output that is of interest to the stakeholders
How to calculate sigma levels
# of opportunities - # of defects) # of opportunities. X 100 = Yield.
Quality process improvement methodologies first became elements of business management practices in the 1990s.
False
Six Sigma methodology was created and introduced to industry by the American Society for Quality (ASQ).
False
What is Value Stream
A value stream is all the steps (both value added and non-value added) in a process that the customer is willing to pay for in order to bring a product or service through the main flows essential to producing that product or service.
The totality of features and characteristics of a product or service that bear on its ability to satisfy stated or implied needs".
ASQC
Which DMAIC phase use the Lean Six Sigma metrics of Sigma, DPMO, or Value-added time?
All phases
What does ANOVA stands for
Analysis of Variance.
In what project phase do you Identify sources of variation and waste.
Analyze
What is beta testing?
Beta testing is the act of implementing a new idea, system, or product with a select group of people or processes in as controlled an environment as possible.
Which Lean Six Sigma Belt is normally a full time project leadership role?
Black Belt
Appraisal cost or prevention cost is found where?
COGQ Cost of Good Quality
The solutions developed in the improve phase of a lean 6 Sigma project and implemented in the control phase will often require (what) expenses.
COGQ Cost of Good Quality
Establish plans and procedures to ensure that your improvements are sustained.
Control
In what project phase do you Implement the Control Plan.
Control
In what project phase do you ensure organizational change actions are complete.
Control
What project phase does the project deliverable does, Close the project
Control
What project phase does the project deliverable does, Control Plan for the new process
Control
What does CAPA stands for
Corrective Action and Preventive Action.
What does COPQ stand for?
Cost of Poor Quality.
using the acronym, "DOWNTIME", which stands for:
Defects Overproduction Waiting Non-utilized talent Transportation excess Inventory excess Motion excess Excess processing
What is the acronym DPMO
Defects per Million Opportunities.
Which 6 sigma methodology is most applicable to examining and improving the customer relations side of a company,
DMADV
Which 6 sigma methodology is used in the creation of a new product?
DMADV
What is the acronym DPU?
Defects per Unit.
In what project phase do you Map the process.
Define Measure and Improve
During which phase is cost of quality (COQ) used?
Define and Control
Which Lean Six Sigma phases provide a practical statement of the project's problem to be solved?
Define and Measure
When to use the process management techniques?
During the measure, analyze, improve, and control phases of the project
By combining Lean Manufacturing and Six Sigma, what does the new methodology focus on for achieving improvement?
Eliminating both waste and variation in the process
What is the primary objective of a Lean Manufacturing analysis?
Eliminating waste
The probability that given unit can successfully pass through a process step without rework or repair.
First-Time Yield - FTY
What type of problem characteristics is the Is / Is Not technique well suited for analyzing?
Inconsistent or intermittent problems
Who normally administers the Lean Six Sigma program in a company?
Master Black Belt
Which of these are classified as Cost of Poor Quality (COPQ)?
Rework and Warranties
What does the acronym SIPOC stand for?
Supplier, Input, Process, Output, Customer
When describing process steps for a process map, what attribute of the steps do you want to ensure is included?
The action that occurs
What is the premise of 6 sigma?
The overarching premise of Six Sigma is that variation in a process leads to opportunities for error; opportunities for error then lead to risks for product defects. Product defects—whether in a tangible process or a service—lead to poor customer satisfaction.
Which set of possible criteria are appropriate to use when selecting a Lean Six Sigma project?
The process is a key to achieving strategic goals and it generates a large quantity of defects
What are two of the common measurements used in Lean Manufacturing?
Throughput and value added effort
6 sigma aims to reduce
Time Defects Variability
What does "value-added effort" mean as it applies to a process step?
Value added effort is the activity, or portion of an activity, that is adding an element of customer value to an item flowing through a process
Six sigma tools help to understand "How" something is done. What do Lean tools help us understand?
When something is done
What is the Is/Is not technique?
a series of declarative statements about the problem
During which phase is data collected or analyzed?
all phases of a Lean Six Sigma project
Technically, in a Six Sigma process
there are only 3.4 defects per million opportunities.
Which data include time, temperature, distance, dimensions, and percentages?
variable data
What is the major differences between attribute and variable data?
variable data can take on an infinite number of values and attribute data cannot.
What best describes the primary characteristic of a process?
A series of actions
When using the "Why?" technique for developing a problem statement, how many times should you ask Why?
As many times as it takes to get from symptom to root cause(s)
What does CTQ stand for?
Critical-to-Quality.
What types of CTQs are externally facing?
Customer CTQs
What is the DOWNTIME acronym?
Defects, Overproduction, Waiting, Non-utilized Talent, Transportation, Inventory Excess, Motion Waste, Excess Processing.
In what project phase do you Create high level process map
Define
Set the context and objectives for your improvement project.
Define
When is project selection initiated?
Define phase
In which phase of a Lean Six Sigma project are project deliverables created?
Deliverables are created in all phases
What is one of the primary uses of a project charter?
Establish the project boundaries
Degree to which a set of inherent characteristics, of a product or service, fulfill requirements".
ISO
Lean Six Sigma projects often use the metrics cycle time and RTY. What improvement methodology originated these metrics?
Lean Manufacturing
What are the units of COPQ?
Money or currency
In Lean Six Sigma projects, what does the "F" in the Y=F(x) formula represent?
The "F" represents the functional interaction of all the inputs and controls that created the process output
What is the disadvantage of launching ideas into beta—or to an entire population--without going through a Six Sigma methodology?
organizations can experience unintended consequences from changes, spend money on ideas that don't end up working out as planned, and impact customer perceptions through trial-and-error periods rife with opportunities for error.
What are the major risks to process performance?
Variation and waste
What is a key component of process mapping?
Walk the process or Gemba walk.
1.What is another way of stating the Pareto principle?
80 / 20 rule
The problem solution is created and implemented in the final two phases of the Six Sigma DMAIC.
True
What project phase does the project deliverable does, Project team members
Define
Lean manufacturing was created in Toyota following World War II.
True
Measure is one of the five phases of Six Sigma DMAIC.
True
What are the 4 activities of quality when meeting the expectation of customers?
*Understanding customer requirements. • Designing products and services that satisfy those requirements. • Developing processes that are capable of producing those products and services. • Controlling and managing those processes so they consistently deliver to their capabilities.
What project phase does the project deliverable does, Project customers and stakeholders
Define
What are the Critical to Quality (CTQ) attributes of a Lean Six Sigma project?
A list of the customer needs
What is the difference between customer need and customer requirements?
Customer needs are what the customer would like to do with the process output. Customer requirements are derived from the needs and are the measurable process targets that should enable the customer to do what they want to do with the process output
In what project phase do you Set the improvement goal.
Analyze
Use data and tools to understand the cause-and-effect relationships in your process or system.
Analyze
What project phase does the project deliverable does Identify sources of variation
Analyze
What project phase does the project deliverable does, Define magnitude of potential improvement
Analyze
What project phase does the project deliverable does, Determine root cause or causes
Analyze
In what project phase do you Determine current process performance.
Analyze Control
What project phase does the project deliverable does Determine Y=f(x)
Analyze and Improve
Under what circumstances would a Lean Six Sigma project team use the deliverables from one phase in another phase?
Any and all circumstances
What our cost of checking your process activities to be certain no errors have been introduced?
Appraisal cost
What percentage of questions must be answered correct on the IASSC Lean Six Sigma belt exams?
Approximately 77% - some questions are weighted differently so the level can vary slightly
What data is expressed in descriptive terms such as: on/off, true/false, Brazil/Argentina/Chile, First place/Second place/Third place, or Good/Better/Best.
Attribute data
What data is used to indicate a status or condition of the process or problem.
Attribute data
Which "Belts" normally lead Lean Six Sigma projects?
Black Belts and Green Belts normally lead projects
What term is used as the cost of preventing problems, or of finding them early in the process so that they can be fixed before additional effort is spent on the item.
COGQ Cost of Good Quality
Quality is defined as knowledge of agents that would enable them to provide accurate and consistent solution to the customer at the very first attempt".
COPC
Lean 6 Sigma projects are chartered to resolve (what problems) since in these cases, the problem is already known to exist.
COPQ Cost of Poor Quality
What is the cost of fixing quality problems?
COPQ Cost of Poor Quality
What two estimates (at a minimum) are needed to prepare a project business case?
Costs and Benefits
In what project phase do you Develop Project Charter
Define
The total amount of time required to move a unit through all the stages in a process including both active working time and delay time.
Cycle time
Which 6 sigma methodology is most commonly used?
DMAIC
Which 6 sigma methodology is used in manufacturing or production side of a product or service,
DMAIC
What are the two methodologies of 6 sigma
DMAIC DMADV
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.
DPMO - Defects per Million Opportunities
What are two of the common measurements used in Six Sigma? 6
DPMO and process sigma
The average number of observed defects on the unit in production.
DPU - Defects per Unit
What are the DMADV stages?
Define - address customer needs in relation to a product or service Measure - involve the use of electronic data collection to measure customer needs, response to product, or review of services Analyze - utilize metrics to evaluate areas where product or service can be better aligned to customer goals and needs Design - overlap the improvement of business processes that streamline corporate goals to best meet client and customer needs Verify - build a system of tests and models to check that customer specifications are being met through on-going improvements
What are the DMAIC stages?
Define - address the identification of specific processes to be examined Measure - record data and use metrics to track effectiveness and evaluate efficiencies Analyze - utilize critical thinking skills to review data and clarify goals Improve - create changes in business processes geared toward improvement and better alignment with corporate goals Control - build a system of checks and adjustments for ongoing improvement in production processes
Which phase is VOC found
Define phase
In which phase or phases should a Lean Six Sigma team be creating process maps?
Define, Measure, and Improve
What phases of a Lean Six Sigma project are covered in the IASSC Yellow Belt Body of Knowledge?
Define, measure, Control
Quality is defined from the customer's point of view as anything that enhances their satisfaction".
Deming
What does DFSS stand for?
Design for Six Sigma.
What is the primary objective of a Six Sigma analysis?
Eliminating waste
A Green Belt position is normally a full-time Lean Six Sigma job.
False
A Master Black Belt decides what Lean Six Sigma projects should be initiated.
False
Ferdinand DeLesseps and Sir Henry James were early leaders in the quality process improvement efforts in Europe.
False
Lean Six Sigma uses statistical measures instead of process measures.
False
One difference between Lean and Six Sigma is that Lean analyzes the process performance and Six Sigma analyzes data.
False
The set of activity (or activities) in the process that result in reduction of quality or efficiency of a business process or manufacturing department, and is not known to managers or others seeking to improve the process.
Hidden Factory
Should a problem statement for a Lean Six Sigma project include the root cause or causes?
If the cause or causes are obvious from the initial data it is acceptable to include them
Develop the modifications that lead to a validated improvement in your process or system.
Improve
In what project phase do you Develop an Improvement strategy.
Improve
In what project phase do you Screen potential problems.
Improve
In what project phase do you Test the solution.
Improve
In which phase does the Lean Six Sigma team conduct initial testing of their solution to the project's problem?
Improve
What project phase does the project deliverable does, Perform a Design of Experiments study
Improve
What project phase does the project deliverable does, Test prototype of simulation
Improve
"Fitness for use. Those product features which meet the needs of customers and thereby provide product satisfaction. Freedom from deficiencies".
Juran
By combining Lean Manufacturing and Six Sigma into one methodology, what types of data no longer need to be analyzed?
Lean Six Sigma analyzes all the same data that both Lean Manufacturing or Six Sigma analyzes on their own
What is the 5's disciplines
Sort, straighten, shine, standardize, sustain
Which set represents three of the six M's that are used for developing problem statements?
Manpower, Methods, Mother Nature
In order to create business improvement, what does Lean Manufacturing try to optimize?
Manufacturing process flow
Who normally selects the business process that is to be the focus of a Lean Six Sigma project?
Master Black Belt and business stakeholders
What are the six M's for the potential categories of root causes?
Materials, Manpower, Machines, Methods, Measurements, and Mother Nature
Determine the baseline performance and capability of the process or system you're improving.
Measure
In what project phase do you Define Performance Standards.
Measure
What project phase does the project deliverable does, Collect data
Measure
Reliability: We want our customers to know that they'll always get a certain level of quality from us. Also, we'll often have a Service Level Agreement or similar in place. Consequently, every product needs to fit specific parameters. Costs: Variation costs money. So to lower costs, we need to keep levels low.
Measure Variation
In which phase of a Lean Six Sigma project should the Lean Six Sigma project team write the problem statement?
Measure phase
What are cost of the activities that are done to eliminate the generation of errors.
Prevention costs
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 the FTY for each step.
Rolled Throughput Yield - RTY
Identifies the process boundaries by clarifying the first and last step and determining the inputs and outputs for the process.
SIPOC
The standard deviation of a population of data. It is used as a scaling factor to compare the process variation against specification limits.
Sigma
Who created 6 sigma and when
Six Sigma was developed by Bill Smith in 1986. Then an engineer at Motorola aimed to help improve the company's devices which didn't meet the quality standards at the time. He based the approach on statistical and quality control methods taught by Walter Shewhart, Ronald Fisher, and Edwards Deming.
What is 6 sigma?
Six Sigma, or 6σ, is both a methodology for process improvement and a statistical concept that seeks to define the variation inherent in any process.
Define the 5's
Sort - Separating items into proper categories. Straighten - Arrange the work space for easy flow and close proximity to where they are used. Shine - Clean the workspace daily, improving safety and reducing maintenance. Standardize - Everything in its right place and everyone following the best practice. Sustain - Self-discipline until it becomes a habit - reinforced with training and audits.
What are the Five S disciplines?
Sort, Straighten, Shine, Standardize, Sustain
What is the acronym SIPOC?
Supplier, Input, Process, Output, Customer
What are techniques that you could use to gather Voice of the Customer data from external customers?
Surveys and focus groups
What does the Taguchi Loss Function indicate?
System losses due to process variation
What is the acronym for the seven categories of waste?
TIM WOOD
What is a common trait of an As-Is process flow for processes that have not been improved with a Lean Six Sigma project?
Tangled flow
What Lean Six Sigma tool or technique can stakeholders use to prioritize which business process should be selected for analysis using the Lean Six Sigma methodology?
The Pareto principle
Lean Six Sigma Yellow Belt team members are normally product or process subject matter experts.
True
Lean Six Sigma follows a structured project management methodology.
True
What is the why technique and how many times is the why question asked?
The Why technique is used to move from symptoms to root causes. It normally takes anywhere from four to eight Why questions to reach a root cause.
Who determines whether an activity is value added?
The customer based upon their definition of value
When sitting for a Lean Six Sigma belt exam through the IASSC, what is one of the exam protocol restrictions?
The exam is proctored
What is the purpose of beta testing
The purpose of beta testing is to reduce the risks and costs inherent in launching an unproven product or system to a widespread audience.
What are Lean Six Sigma project deliverables?
The results of completing project activities which are delivered to the stakeholders
Lean Six Sigma projects strive to eliminate both waste and variation.
True
How do you decide which Lean Six Sigma project metrics to use?
The stakeholders will normally determine them
Lean Six Sigma uses the DMAIC approach for project planning.
True
What are the 7 categories of waste?
Transport - Unnecessary transport of product or goods. Inventory - High inventories greater than necessary. Movement - Unnecessary movement of employees. Waiting - Waiting for the next process step. Over-production - Production ahead of demand. Over-processing - Performing unnecessary steps. Defects - Correcting defective parts.
Considering the seven categories of waste, what is the difference between transport and movement?
Transport deals with unnecessary movement of product or items being processes and movement deals with unnecessary movement of people who perform the process
What is the acronym TIM WOOD?
Transport, inventory, movement, waiting, overproduction, over processing, defects
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
Kaoru Ishikawa and Genichi Taguchi were leaders in the quality process improvement efforts in Japan.
True
Lean Manufacturing methodology creates an "As-Is" Value Stream Map so as to understand areas of process waste.
True
Define VOC
Voice of Customer is the customer's voice, expectations, preferences, comments, of a product or service in discussion. It is the statement made by the customer on a particular product or service.
What is VOC in 6 sigma?
Voice of the customer
What question do we ask about product or process functions that help us to create CTQs?
What does that mean?
What questions will a Lean Six Sigma project problem statement normally answer?
What? When? Where? Who? As they apply to the problem impact
On a Lean Six Sigma project, when would you apply the Pareto Principle?
Whenever you wanted to prioritize between items in a set and you had a measured attribute for each of the items
6 sigma in percentages
means 99.99966 percent of the products from a Six Sigma process are without defect.
What project phase does the project deliverable does, Establish process capability
measure and control
At just one sigma level below—5σ, or 99.97 percent accuracy
processes experience 233 errors per million opportunities.