Lean six

A high level process map constructed in the Define Phase at a minimum must include: (check all that apply) start and stop points value categories directional flow all decision points all process steps

start and stop points value categories directional flow all decision points all process steps

Applying Statistical Process Control to only the process outputs is better known as ___________________________

statistical process monitoring

seiton

straighten

shitsuke

sustain

A VIF between 5 and 10 indicates

that the regression coefficients are poorly estimated and are unacceptable

A Multivariate Regression model with a high R-Squared value establishes a cause and effect relationship between the out response Y and the input variables X. T/F

false

A goal of the Pareto analysis in an LSS project is to assist you in determining what inputs have the least impact on your process. T/F

false

A process is a non-repetitive series of unorganized steps or activities where inputs are modified to achieve value-added output. T/F

false

A rental car agency is testing two brands of radial tires. The agency assigns one tire of each brand at random to the two rear wheels of eight cars and runs the cars until the tires wear out. The data provided below is in miles. Brand 1 Brand 2 36,925 34,318 45,300 42,270 36,745 35, 600 32,100 31,175 37, 250 38,470 48,390 47,600 38,200 37,950 33,500 33,225 Based on the data provided, your would prefer Brand 1 over Brand 2 at the 95% CL T/F

false

Conveyance is an element of waste. Conveyance is the necessary movement of material and goods. T/F

false

Cp is computed as: (closest Spec Limit - sample mean)/6S T/F

false

Cycle time is the "touch time" of the value added portion of the process. T/F

false

Cyclical variation is variation across a single unit containing many parts. T/F

false

DOE allows experimenters to study the effect of many input variables that may influence the product or process one at a time as well as identify possible interaction effects. T/F

false

Defect prevention seeks to gain permanency by adding human intervention. T/F

false

Discrete data is always more desirable for statistical analysis T/F

false

FMEA is an unstructured approach that is designed to help eliminate X's in your process. T/F

false

If a process is not capable then you must find a way to shift the process. T/F

false

If a process is not centered then you must find a way to reduce the variation. T/F

false

Kanban is a technique used to "push" products and material through the system. T/F

false

Measurement system analysis is only applicable to about 50% of projects and often times has an insignificant effect on the success of a project. T/F

false

Multi-Vari Carts can be used to assess capability, stability, and statistical relationships between X's and Y's. T/F

false

Narrowing the specification limits is a reasonable problem-solving option for an incapable process T/F

false

Poor Correlation allows for tighter tolerances T/F

false

Reproducibility is the variation in measurements obtained by one individual measuring the same characteristic on the same item with the same measuring instrument. T/F

false

SPC is used to detect common cause variation telling us the process is "out of control" T/F

false

Six Sigma created a realistic and quantifiable goal in terms of its target of 3 defects per million operations. T/F

false

Six Sigma makes people into statisticians in order to be excellent problem solvers. T/F

false

Six Sigma starts with a practical problem, translates it into a statistical problem, corrects the practical problem then validates the statistical problem. T/F

false

The amount of difference, change, or improvement that will be of economic or technical value to you is known as statistical significance. T/F

false

The central limit states that as the sample size becomes large, then the sample mean distribution will form a normal distribution only if the population distribution of individuals is normally distributed T/F

false

The interquartile range is the difference between the 90th percentile and the 30th percentile. T/F

false

The least common operator/machine errors have to do with someone misreading a value, recording a value incorrectly or the fixture holding the part is poor. T/F

false

The level 2 process flow map usually contains estimates of defects-per-unit, flow throughput yield and roll throughput yield T/F

false

The primary purpose of linear correlation is to measure the strength of a non-linear association between two variables (X and Y) T/F

false

The regression equation with a high R-squared value identifies a strong cause and effect relationship. T/F

false

The second stage of 5S, Shining, is keeping everything clean and swept T/F

false

The strength of the "lean" concept is effectiveness. T/F

false

The three components of a financial evaluation are Impact, Forecast, and KPI's T/F

false

Two different etching solutions are being compared for a semiconductor manufacturing process. The etch rate is known to follow a normal distribution. Using two random samples of 10 Wafers for each etch solution, the following etch rates were observed: Sample 1 9.9, 9.4, 9.3, 9.6, 9.8, 10.2, 10.4, 10.3, 10.1, 10.0 Sample 2 10.2, 10.6, 10.7, 10.4, 10.0, 10.2, 10.4, 10.2, 10.5, 10.3 The data supports the claim that the mean etch rate is the same for both etching solutions at the alpha=0.05 level. T/F

false

Unit to Unit Variation is a type of measurement system error. T/F

false

We can sustain a visual factory without 5S T/F

false

When selecting projects, the starting point is defined by the Champion or process owner with the Benefits analysis as the output. T/F

false

When studying two samples, there may be a real difference between the two samples; however, we may not be able to determine s statistical difference. Our ability to detect a difference is only driven by the sample size? T/F

false

When the average of a set of measurements is on target we say the measurement is precise. T/F

false

When viewing an interaction plot, the lines must actually cross each other in the figure for an interaction to exist? T/F

false

for our process, Y = f (xi) if we are good at controlling and choosing the xi's then we need to constantly test and inspect Y? T/F

false

First Time Yield is the appropriate metric for problem solving because it accounts for any necessary rework. T/F

false (Rolled Throughput Yield, RTY is the most appropriate metric for problem solving because it accounts for losses due to rework)

In a Six Sigma organization aA Green Belt serves as the Project Team lead, facilitates DMAIC teams in applying Six Sigma methods, works cross functionally, contributes to the organizational goals, and provides technical support to improvements efforts. T/F

false (black belt)

A Master Black Belt (MBB) owns project selection, execution control, implementation and realization of gains. T/F

false (champion)

In process mapping, a parallelogram indicates an activity. T/F

false (decision)

A crossed design is used for destructive testing and also situations where it is not possible to have all operators or machines measure all the parts multiple times. T/F

false (nested is destructive)

In a six sigma process, it is necessary to clearly understand the customers needs, we call this "understanding the CTp's or Critical to Process. T/F

false (should be CTQ critical to customer)

Bartlett's Test is used to compare the estimated population standard deviations from two or more samples with Non-Normal Data T/F

false (should be levins)

What type of DOE design is used when the process or product knowledge is low and there is a long list of possible input variables.

fractional factorial

Which of the following are the primary causes for Non-Normal Data? (check all that apply) ? granularity of data natural and artificial limits multiple modes kurtosis

granularity of data natural and artificial limits multiple modes kurtosis

Process Interruptions are mechanisms installed that shut down the process and prevent further operation until a required action is completed. Which of the following is an example of a process interruption

ground fault interrupt

Which of the following reasons for a designed experiment creates a mathematical model designed to move the process response. problem solving screening optimizing robust design

optimizing

Capability is defined as:

output variation width divided by specification width

The ___________ chart plots the proportion of nonconforming units collected from subgroups of equal or unequal size.

p

Which of the following types of process control that are in place to prevent failure? (check all that apply) kaizen poke-yoka spc 5s

poke-yoka spc

Which of the following are not categorical headings for a product in a cause and effect diagram (check all that apply) measurement policy people place method

policy place

Poor measures can result from: (check all that apply) representative poor sampling inaccurate measurement devises relevant poor or non existent operational definitions difficult measures

poor sampling inaccurate measurement devises poor or non existent operational definitions difficult measures

VOE is "_______" Driven

process

Which of the following constitute the minimum set of deliverables for a project: (Select all that apply) detailed schedule project charter benefits analysis business case

project charter benefits analysis business case

Which of the following are potential roadblocks to an LSS project? project is scoped too broadly no historical data exists the team creates the "as is" process map excess inventory the team creates the "ideal" process map team members have time to collect data

project is scoped too broadly no historical data exists the team creates the "ideal" process map

Which of the following is not a measure Accuracy? repeatability resolution bias stability

repeatability

_________________ is the variation in measurements obtained with one measurement instrument used several times by one operator while measuring the identical characteristics on the same part.

repeatability

Appropriate measures are: (check all that apply) Representative Static Relevant Sufficient Contextual

representative relevant sufficient contextual representative

Generally speaking, COPQ can classified a tangible ( Visible, easy to see) and intangible (Hidden, difficult to see). Which of the following are examples of visible costs? late delivery rework warranty inspection lost sales

rework warranty inspection

Which of the following reasons for designed experiments desensitizes the output response to input variable changes including noise variables.

robust design

Suppose you are studying a process that has 3 steps all of which must completed in sequence. Suppose step 1 has a DPU of 0.01, step 2 has a DPU of 0.05, and step 3 has a DPU of 0.025. What is the the RTY for the process and what is the DPU for the process?

rty=.9185 dpu=.085

Why do we Straighten when performing 5S (check all that apply) saves time by not needing to search increases travel distance visually identifies what is missing or out of place more efficient to find items

saves time by not needing to search visually identifies what is missing or out of place more efficient to find items

seiso

shine

Which of the following is a type of process map? (check all that apply) sicop map value stream map swim lane map linear flow map

sicop value stream swim lane linear flow

seiri

sort

seiketsu

standardize

Levene's Test of Equal Variance is used to compare the estimated population standard deviation from two or more samples with Non-Normal Distributions. T/F

true

Measurement Error is defined as the effect of all sources of measurement variability that cause an observed value to deviate from the true value. T/F

true

OFAT is inefficient when compared with DOE . T/F

true

Process mapping is a powerful tool you will use to improve the effectiveness and efficiency of a process. T/F

true

Range is typically used for small data sets. T/F

true

Sampling frequency is a balance between the cost of sampling and testing versus the cost of not detecting shifts in mean or variation T/F

true

Six Sigma places emphasis on the process. T/F

true

Six Sigma puts strong emphasis on the customer because they are the ones assessing our performance and they respond by either continuing to purchase our products or services or NOT! T/F

true

Stability is Bias characterized as a function of time T/F

true

Statistics is the basic language of Six Sigma. T/F

true

The 'Null Hypothesis" assumes that there is no differences or relationships and is the default hypothesis of all statistical tests. T/F

true

The 5th stage of 5S is sustaining, to maintain our discipline, we need to practice and repeat until it becomes a way of life. T/F

true

The cause and effect diagram is a tool to generate opinions about possible causes for defects. T/F

true

The components of variation in a measurement system are statistically additive. T/F

true

The first activity of the Measure Phase is to adequately describe the process under investigation. T/F

true

The fourth stage of 5S, Standardizing, involves creating a consistent approach for carrying out tasks and procedures. Orderliness is the core of "Standardization". T/F

true

The goal of the Define Phase is to identify a process to improve and develop a specific lean six sigma project T/F

true

The larger the subgroup size the greater the chance of detecting a special cause. T/F

true

The power of the test is the probability of rejecting the null hypothesis Ho when the alternative hypothesis is true. T/F

true

The primary contributors to measurement system error are repeatability and reproducibility. T/F

true

The primary purpose of linear correlation analysis is to measure the strength of linear association between two variables (X and Y) T/F

true

The vision of lean supporting your project is to achieve and sustain improvements. T/F

true

When dealing with Non-Normal Data, one test the equality of medians instead of the equality of means. T/F

true

While many processes in nature behave according to the Normal Distribution, many processes in business, particularly in the areas of service and transactions do not. T/F

true

X-Sifting is used to determine what the impact of the inputs to the process are on the output T/F

true

An improvement made to the process will detect when an error condition has occurred, setting a flag that shuts down the equipment so the defect does not move forward is known as a __________________________

type 2 corrective action

What type of chart plots defects per unit data collected from subgroups of equal or unequal sizes?

u chart

The Voice of the customer is import to understanding the CTQ's. Which of the following aid in understanding the customer? understand the delivery mechanisms and determine whether the process meets customer time frame understand the customers strengths and weaknesses understand the customers perspective on features understand the customers perceived value vs cost

understand the customers perspective on features understand the customers perceived value vs cost understand the delivery mechanisms and determine whether the process meets customers time frame

The correlation coefficient always takes on a value between ___________ and ____________.

-1 and 1

DPU is a measure of the average number of defects per unit. Suppose you have sampled nine lap top computers, Three of the laptops are defective. One of them has a bad video card, Another one has a bad screen, a bad battery, and a bad camera. A third has 2 bad keys on the keyboard. What is DPU rate for laptops?

.667

A general guideline for practical significance is:If open vertical bar r close vertical bar space greater than space ________, the relationship between X and Y is practically significant

.80

A minimum of X observations is needed to effectively generate a Box plot.

10

As a general rule, long term data consists of

100 to 200 data points over an extended time

The special cause detection rules that are visually the most easily detected are: (check all that apply) 2 out of 3 consecutive points more than 2 standard deviations from the center line 15 points in a row all within 1 stdev of either side of the center line one point more than 3 stdev from center line 6 points in a row all either increasing or decreasing

15 points in a row all within 1 standard deviation of either side of the center line one point more than 3 stdev from center line

A 2^(4-1) fractional factorial experiment, with 2 replications will have how many total runs?

16

A 4-factor full factorial experiment will have how many total runs

16

The standard error approaches zero at about ______________ samples

30

In order for Kanbans to succeed you need each of the following: (check all that apply) ongoing kaizen 5s visual factory standardized work

5s visual factory ongoing kaizen standardized work

The phrase "lean manufacturing" is credited to

James Womac

An appropriate number of distinct categories necessary to estimate process parameters is:

5 or more

An Attribute Gage R&R study requires a minimum of

5 times as many samples as a continuous study

It has been correctly stated that X % of the success of the project is dependent on how well the effort has been defined.

50%

We cannot sustain standardized work without _______________ (check all that apply) 5s kanban visual factory kaizen

5s visual factory

Which of the following statements are correct about 5S (check all that apply) 5s is derived from the Chinese words for five practices leading to a manageable work area 5s is the starting point for implementing improvements to a process 5s means the workplace is clean, there is a place for everything and everything is in its place its strength depends upon the employees and the company being committed to and maintaining it

5s is the starting point for implementing improvements to a process 5s means the workplace is clean, there is a place for everything and everything is in its place its strength depends upon the employees and the company being committed to and maintaining it

How many basic elements of Muda are there?

7

A "3 Sigma" process has a

93% yield

A " 5 sigma process" produces 3.4 PPMO T/F

false

Incorrect data entry, paying the wrong vendor, making a bad product, are all examples of what component of Muda?

Correction

COPQ is a defect not a symptom. T/F

False

Which of the following are measures of precision?

Repeatability and reproducibility

A DOE model is known by theory using concepts of physics, chemistry, biology, etc. and explains relationships outside the area of immediate project needs. T/F

false

Why does Six Sigma have a process focus? A. so we can understand how and why work gets done B. To characterize customer & Supplier relationships C. To Manage for maximum Customer satisfaction while utilizing maximum resources D. To see the process from start to finish as it is currently being performed E. To identify and define defects: Blame the process and the people

a b d

The most desirable approach to Project Selection is:

a structured approach

For a gage used in a study where the variance is between 10-20% and the gage contributes 1-4% is

acceptable

Which of the following is not a characteristic of the normal distribution? All processes exhibit a normal curve shape the distribution is mounded and symmetric the mean divides the area in half for a normal distribution the mean median and mode are the same data point for a normal distribution

all processes exhibit a normal curve shape

The R-squared value estimates the _________________________

amount of variation explained by the model

There are two primary types of data. They are

attribute data and variable data

Which of the following is not a "good" six sigma behavior? avoiding change making data-based decisions embracing change and continuous learning being tenacious, courageous

avoiding change

The components of a business case are: (check all that apply) baseline performance of primary business measure output unit for external customer gap in the baseline performance of the primary business measure from the business objective a primary business measure of output unit for project

baseline performance of primary business measure output unit for external customer gap in the baseline performance of the primary business measure from the business objective a primary business measure of output unit for project

Regression Analysis relies on assumptions about the residuals. The following assumptions about the residuals must be met: (check all that apply) be normally distributed be independent of each other be correlated have a constant variance

be normally distributed be independent of each other have a constant variance

The higher the "sigma level" of a process the .....

better the process

Which of the following are reasons for Multiple modes in your data? catastrophic failures mixtures of distributions dependence independence

catastrophic failure mixtures of distributions dependence

For each of the X's identified in your cause and effect diagram you should classify them as follows: (check all that apply) controllable environment noise equipment procedural

controllable noise procedural

Which of the following are examples of COPQ Soft savings? customer loyalty labor savings scrap reduction missed opportunities

customer loyalty missed opportunities

Which of the following are the classical sources of variation? (check all that apply) cyclical positional static temporal

cyclical positional temporal

A customer service group is interested in estimating the Capability of their call center. A total of 10,000 calls came in during the month but 1500 dropped before they were answered (caller hung up). Find the DPU and Cpk for the process.

dpu = .15 cpk= .845

The goal of lean controls is to sustain your project by _____________________ Muda

eliminating

When you find that two inputs have a large impact on the output Y, but do not have an effect on Y by themselves, then this is called a __________________

interaction

The philosophy of continual improvement, that every process can and should be continually evaluated and improved in terms of time required, resources used, resultant quality and other aspects relevant to the process is know as:

kaizen

__________ is defined as the difference in bias value throughout the measurement range in which the gage (instrument) is intended to be used.

linearity

The following are measure location (check all that apply) range variance mean mode

mean mode

In general, which measure of location is the mid-point or 50th percentile of the data?

median

The following questions are examples of what type of product category? How is this performed? Are Procedures correct? What might be unusual?

method

If a process is both incapable and not centered, then you must:

minimize and get control of the variation first

Extra steps, extra data entry, and having to look for something are examples of what component of Muda

motion

Our goal in Six Sigma is to improve our process capability. We can do this by doing each of the following: (check all that apply) move the process mean reduce the process variation reduce the process mean and reduce the stdev move the process mean and reduce process variation

move the process mean reduce the process variation move the process mean and reduce the process variation

What type of chart shows the individual data points that are represented in a Box plot?

multi-vari chart

Suppose you have non-normal data and the variances are found to be unequal. The unequal variances are usually the result of (check all that apply) multiple modes extreme tails outliers large sample size

multiple modes extreme tails outliers

Which of the following is not a reason for creating a process map? my boss said so it can help understand where problems occur and what some causes may be it can be used as an aid in training it will show you where you can take measurements that will help you to run the process better

my boss said so

The correlation is ______________ when Y tends to decreases with an increase in X and ____________ when Y tends to increase with and increase in X

negative, positive

__________________ occurs when the X and Y scales are different for a given change in X

non-linear realtionship

Which of the following can be used to assess the normality of a data set? (check all that apply) time series plot box plot normal prob test anderson-darling test

norm prob test anderson-darling test

Short term data is characterized by these types of conditions: (check all that apply) many employees many suppliers one batch one shift

one batch one shift

Which of the following are types of cost impacts? direct costs indirect costs one off sustainable

one off sustainable

Which of the following are examples of discrete data? (check all that apply) The number of defective needles in boxes of 200 diabetic syringes the number of surveys returned out of 500 mailed the body temperature for a hospital patient the length of prison time served for individuals convicted of first degree murder

the number of defective needles in boxes of 200 diabetic syringes the number of surveys returned out of 500 mailed

A "3 Sigma" process has a higher COPQ than a "5 sigma" process T/F

true

A Process baseline implies long term performance. T/F

true

A designed experiment can be used to establish a true cause and effect relationship T/F

true

A project COPQ represents the financial opportunity to your teams improvement effort (VOB). T/F

true

A swim lane chart is a cross-functional high level process map where the lines drawn horizontally across the map represent different departments in the company. T/F

true

Although brainstorming can be very structured, it falls far short of being a systematic means of identifying projects that will reduce the COPQ throughout the organization. T/F

true

An experiment is performed in which 17 Golf Club Drivers produced by a particular manufacturer were selected at random and their coefficient of restitution measured. Suppose the mean of the sample is 0.8375, and the Standard deviation is 0.025. Suppose a normal probability plot confirms that the data is normal. Given the following Hypothesis: Ho: Mean =0.82 Ha: Mean > 0.82 Alpha =0.5 Given the data provided, you would reject the null hypothesis and conclude the mean is greater than 0.82 T/F

true

Attribute data is always long term in the shifted condition since it requires so many samples to get a good estimate with reasonable confidence. T/F

true

Before you invest a lot of time analyzing data you must ensure that data has integrity. T/F

true

Brainstorming techniques work because the knowledge and ideas of two or more persons is always greater than that of one individual T/F

true

Business measures are a function of processes. Processes are usually made up of a series of activities. T/F

true

Capability analysis compares the voice of the process to the voice customer. T/F

true

Control charts indicate when a process is "out of control" but not why. T/F

true

FMEA's help you manage risk for your process T/F

true

Five items made at the same time on different machines are not a rational subgroup. T/F

true

For short term data, you are "controlling" all the controllable sources of variation T/F

true

For some input variables, your team may choose to not control them because you think the cost does not justify it? T/F

true

For the normal distribution, the mean equals the mode and the median. T/F

true

I and MR charts are used when each measurement represents 1 batch. The subgroup size for an I-MR chart is equal to one. T/F

true

If all operators have the same repeatability and it is too big the gage needs to be repaired or replaced T/F

true

If the P-value for your regression model is > 0.05, then you fail to reject the Null Hypothesis Ho: Regression equation is not significant. T/F

true

If your input is Normally distributed about a mean then the output Y may not be Normally distributed T/F

true

In any process improvement endeavor, the ultimate objective is to make the process better, faster, and cheaper. T/F

true

The Six Sigma Problem Solving Methodology focuses on: (check all that apply) understanding the relationship between independent variables and the dependent variable monitoring the optimized independent variable identifying the vital few independent variables that effect the dependent variable optimizing the dependent variables so as to control the independent variable

understanding the relationship between independent variables and the dependent variable identifying the vital few independent variables that effect the dependent variable monitoring the optimized independent variable

Brainstorming falls short of being a systematic means of identifying projects that will reduce COPQ throughout the organization because: (choose all that apply) does not include everyone's thoughts and ideas does not fall short of being systematic means of identifying projects that reduce COPQ usually does not utilize a data based approach, relies on tribal knowledge does not ensure we are dealing with the most important high-impact problems but rather what happens to be the recent firefight initiative

usually does not utilize a data based approach, relies on tribal knowledge does not ensure we are dealing with the most important high-impact problems but rather what happens to be the recent firefight initiative

Select those items that make up the value categories in a high level process map

value added, non value added, value enabling

What type of process map is a specialized map that helps you to understand numerous performance metrics associated primarily with the speed of the process?

value stream map

Process capability measures provide insight as to whether the process has a : (Check all that apply) variation issue centering issue run issue inappropriate specification limits a combination of centering and variation issue

variation issue centering issue inappropriate specification limits a combination of centering and variation issue

The three views of a process are: (check all that apply) what it used to be what you think it is what it should be what it actually is

what you think it is what it should be what it actually is

What type of chart plots the average value of each of a number of small sampled sub groups?

x-bar