Green Belt
Which one of the following describes how to calculate the Cost of Poor Quality for a rework loop?
(Defect rate) x (Volume) x (Cost of rework per unit)
From a leverage perspective, as the team works through the original project , it should try to identify three types of other projects that might benefit from its work. These include...
1. replication projects 2. related projects 3. spin-off projects
There are three types of reactions in a reaction plan. They are...
1. the compensation action 2. Corrective action 3. prevention
Can you guess what percentage of working time in a typical office or administrative organization adds no value when viewed from the customer's perspective?
60-80%
Six Sigma has been described as a commitment to your customers, a statistical measurement of processes, and which of the following?
A management framework for thinking about process economics, quality, and customers
Changeover reduction is best described as:
A structured methodology and technique used to reduce the combined amount of Set-up and Start-up time it takes to change from running one specific calibration or type of product to another
Which of the following allows you to improve the process by removing barriers and enabling flow?
Adjusting all process steps to produce to Takt Time or quicker
A GB's supervisor can support LSS/CI program by...?
All of the above
What is true of rational sub-groups?
All of the above
When should an outlier data point be removed from a control chart, and control limits recalculated?
All of the above
Theory of constraints can be used to improve which of the following processes?
All of the above. Any process
If an application for a credit card is being considered for opportunities for defects, which listed item(s) would qualify as an opportunity?
All of the listed items could be considered as an opportunity
What best defines a Value Stream?
All the activities an organization must complete to generate a product, information, or service
What is one benefit of implementing Lean methodologies within business processes?
An improved response to customer requirements.
Your company decides to institute 100% inspection of a credit card vendor's plastic coating thickness. This change falls under which Cost of Quality category?
Appraisal costs
The Nelson rules identify data points or trends in the data that:
Are mathematically unlikley due to occur by chance
One way a GB's Supervisor can support a project is to...
Assure good change management is used for solution implementation
A product Family refers to a group of products that go through the same or similar process steps, with similar process times and demand rates. How much of the same processing steps are usually shared?
At least 80%
One way a GB's supervisor can promote usage of Lean Six Sigma/Continuous Improvement is to...?
Become familiar with the methodologies and tools the Green Belt are using.
In Office or Service environments, how is waste typically eliminated and real value created for the customer?
By eliminating idle time, bureaucracy, unnecessary redundancy, and other non value-added activities
What are control chart constants used for?
Calculating control limits
Which one of the following techniques is most commonly associated with reducing set-up time?
Changeover reduction
A metric that describes the amount of time elapsed from completion of the last good part of a production run, to the first good part of the next run is known as
Changeover time
A metric that describes the amount of time elapsed from completion of the last good part of a production run, to the first good part of the next run is known as:
Changeover time
What describes the use of a Product Family Matrix?
Compares steps across products and identity families
process adjustment to bring the variable back in control without identifying or correcting the cause is what type of action?
Compensating
Responsibilities for the improvement project will transition from the improvement team to the operations team in which DMAIC phase?
Control
The rope in a theory of constraints system...
Controls material release duration in order to keep the buffer at a certain level
An action in which the cause of variation is identified and corrected temporarily is called...
Corrective action
This type of savings allows an organization to handle more business without adding resources, people or equipment.
Cost avoidance savings
The focus of Lean is to?
Create more value to the customer, use fewer resources, shorten cycle time
A TOC tool which is used to examine the cause and effect logic behind the current situation and which helps determine why that situation is different from its preferred state is the... A intermediate objective map. B current reality tree. C prerequisite tree. D future reality tree.
Current reality tree
Where do leaders get Black Belt project ideas from?
Customer pain points and business imperatives
Which term describes the six sigma road map used for process improvement?
DMAIC
In what DMAIC phase is the Project Charter approved?
Define
In what phase of DMAIC is the Project Charter developed to define the project scope and provide guidance to the improvement team?
Define
In which phase of the DMAIC road map are the customers requirements identified?
Define
At what step of the Lean Roadmap would the GB begin his/her work?
Define Customer Value
At what step of the Lean Roadmap would the GB begin his/her work?
Define customer value
Which of the following roles often serves as the resource for removing roadblocks and resistance?
Deployment Champion
What tools are best used to share lessons learned from projects?
Documentation, communication, and training
Improving flow in an office area is accomplished by?
Eliminating redundance, providing visual tools for tracking progress, combining operations.
Who is responsible for the sponsorship and commitment of an organization to the Lean Methodology?
Executive Champion
How is 5S/6S utilized during Lean improvement activities?
Guides organizations to create and maintain an organized, clean, and safe work environment as a foundation for achieving Lean.
What Lean Principal helps synchronize and control inventory levels, and trigger production in the supplying processes.
Implementing a Pull System
The two biggest reason Lean Six Sigma/Continuous Improvement projects "fail" are...?
Improper support and Poor Management Decisions
In what phase of DMAIC is a solution or solutions identified that will maximize return on investment?
Improve
In what type of process is the customer actually a part of the process?
In a service process
Which category of Cost of Quality would include the cost if a group of new cards is printed today with the wrong expiration date and scrapped before delivery to the customer?
Internal failure costs
In order to understand the foundation of the Theory of Constraints, think of an organization or company in terms of its:
Investments in equipment and inventory
Green belts normally lead an improvement project that...
Involves his/her day to day job functions and is within a process they are very familiar with.
What is the traditional industry target for Changeover Time?
Less than 10 minutes
In which phase of six sigma will the current measurement system be understood and baseline capability estimated?
Measure
Two types of time weighted control charts are:
Moving Average and Exponentially Weighted Moving Average Charts
In a theory of constraints context, policies, rules, measurements, and training are examples of...
Non physical constraint
When starting a typical office improvement project, the improvement team will often find that transactional processes are....?
Not very well defined or documented. As a result it is often difficult to define defects or errors.
Which one of the following describes how to calculate DPMO?
Number of defects divided by the number of opportunities multiplied by one million
Sun-optimization...?
Occurs when each individual function runs at peak performance without considering other functions or needs.
What is the basic difference in detecting waste in manufacturing and transactional environments?
Office output is often intangible and can take the form of information flow
What difficulty is often experienced while implementing Lean within a typical office environment?
Personnel do not welcome change. They are happy the way things are.
Other names for Changeover Reduction are Quick Changeover, Set-up Reduction and...
Process Optimization (wrong) Production Improvement (wrong) Single Minute Exchange of Die
The day-to-day task for monitoring and continual improvement of the process is the responsibility of the...
Process Owner
The buffer in a theory of constraints system... A enforces the pace. B authorizes production. C protects the critical chain. D sets the pace.
Protects the critical chain
One measurement that is often used to measure the impact of a process improvement project on business results is...
ROI
Which of the following statements regarding six sigma is correct?
Reduces variation and eliminates defects
The Lean concepts of Just in Time (JIT) and Continuous Flow focus on?
Responsiveness
Which one of the following best describes "net profit"?
Selling price minus costs
One way a leader can support the LSS/CI program is to...?
Serve on the steering committee that approves black belt projects.
The drum in a theory of constraints system...
Sets the pace
Which Lean tool enables flow by defining the sequence of steps and the time required to perform them?
Standard work
In the chain analogy, the chain represents?
Steps in a value stream
One of the key ideas in Goldratt's theory of constraints is to maximize system performance by... A balancing the production line, i.e., equal capacity at each operation. B strengthening the weakest link the chain. C maximizing production at each operation. D minimizing the buffer.
Strengthening the weakest link the chain.
A person waiting until the last possible moment before fully applying themselves to completing a task is an example of...
Student syndrome
In a Future State Map, what kind of Pull system is an alternative to WIP?
Supermarket
A control plan is a written summary of the systemic approach the team will use to minimize product and process variation. It outlines...
The steps that should be followed to ensure all process outputs are stable and operating within required specifications
In a theory of constraints system, throughout of the process is determined by....
The system constraint, or weak link
In today's terminology, what are processes associated with non-manufacturing areas of business or administration are referred to as?
Transactional processes
Which of the following is NOT a step of Changeover Reduction?
Transfer internal time to external time (wrong) Transfer external time to internal time
Every team member should take an active role in leveraging a project
True
True or False? From a Lean perspective, transactional processes can be broken into two main categories: office and service. The biggest difference between the two is that in service processes, the customer is actually part of the process.
True
What is "leveraging the project"
Turning the knowledge gained during the project into knowledge that can be used across the enterprise
When considering implementation of Lean in your office or service organization, what are some key indicators to look for in the work place?
Unable to complete the job due to redundance and back log
The ___________ is a Lean Six Sigma tool or technique that stresses "learning through Genchi Genbutsu," a Japanese term that means "go and see."
Value Stream Map (wrong) Quality Circle (wrong) Ohno Circle
What type of activities are the customers willing to pay for?
Value-added
Which of the following activities would not be a part of leveraging a project?
Verifying root cause
When would the Z-MR chart be used?
When parts are made in small runs
When can internal activities be performed?
While the equipment is in use (wrong) When the machine is not running
In a Changeover Reduction project, external work is described as
Work that occurs outside a manufacturing facility (wrong) Work that needs to be executed by an external facility (wrong) Work that can occur only when the process is stopped (wrong)
Implementing a control plan in a process does three key things. It establishes a system for continuous monitoring of the process for stability; it corrects any problems as they occur by deploying appropriate corrective action procedures; and it...
allows for a reliable assessment of process capability
Prior to calculating DPMO the improvement team must...
clearly define and agree on the definition of a defect.
There are two parts to the control phase. In the first part, the team focuses on controlling the process. This includes...
collecting data from key points in the process, developing a control plan, and creating a reaction and re-evaluation strategy to ensure the Control Plan is current
A critical tool to ensure that the gains from the project are maintained over time is the...
control plan
An improvement project resulted in an organization performing more work with the same resources. This is an example of...
cost avoidance savings.
One of the final steps in creating a Future State Value Stream Map is...
develop operational Pull Systems between any steps where product cannot flow continuously.
Once the Lean Improvement team completes analysis of the Current State Value Stream Map, their focus becomes documenting process Takt time and...
identifying barriers to flow.
The primary purpose of Changeover Reduction is to...
increase production capacity.
In an I-MR chart, what is plotted in the 'I' portion of the chart?
individual values taken over time
An improvement project resulted in increased job satisfaction. This is an example of...
soft savings.
In an I-MR chart, the MR is calculated by:
taking the positive difference between each measurement and the one immediately preceding it
If a p chart control limit changes from data point to data point, what could be making this happen?
the sub-group size changes
