Sigma Practice Question 6 ( Indian Council / Sigma goals)
An improvement team has completed several RPN values and is not ready to institute improvements. There are 3 failure modes with the same RPN score in the table below. First line time which should be reduced would be? Bad battery---Severity-9;Occurrence= 7; Detection =5 ; RPN= 315 Cracked welds ---Severity-7; Occurrence= 9; Detection =5 ; RPN= 315 Missing bolts------Severity-5 Occurrence= 7; Detection =9 ; RPN= 315 a. Bad battery b/c highest severity rating b. Cracked weld b/c highest occurrence c. Missing bolts because highest detection level d. Rankinga re the same, so choose any one to start
An improvement team has completed several RPN values and is not ready to institute improvements. There are 3 failure modes with the same RPN score in the table below. First line time which should be reduced would be? Bad battery---Severity-9;Occurrence= 7; Detection =5 ; RPN= 315 Cracked welds ---Severity-7; Occurrence= 9; Detection =5 ; RPN= 315 Missing bolts------Severity-5 Occurrence= 7; Detection =9 ; RPN= 315 a. Bad battery b/c highest severity rating b. Cracked weld b/c highest occurrence c. Missing bolts because highest detection level d. Ranking are the same, so choose any one to start A- correct
An organized and disciplined approach to problem-solving in most six sigma organizations is called: A. SIPOC B. DMAIC C. PDCA D. DPMO
An organized and disciplined approach to problem-solving in most six sigma organization is called: A. SIPOC B. DMAIC C. PDCA D. DPMO B= CORRECT... Only two problem-solving approaches listed are DMAIC and PDCA. DMAIC is most closely linked with 6 sigma. PDCA is team-problem solving toll. Section II-4
Analysis of risk involves two measures of failures. These measures are: A. Failure analysis and failure effects B. Failure mode and failure methods C. Failure severity and failure probability D. Failure mechanism and failure mode
Analysis of risk involves two measures of failures. These measures are: A. Failure analysis and failure effects B. Failure mode and failure methods C. Failure severity and failure probability D. Failure mechanism and failure mode C- Correct
Calculate takt time per system data provided: Demand= 30 units/ hour Step 1 @ 20 units/hr Step 2 @ 40 Step 3 @ 12 Step 4@ 16 Step 5@20 A. 5 min B. 1.8 min C. 3 min D. 2 min
Calculate takt time per system data provided: Demand= 30 units/ hour Step 1 @ 20 units/hr Step 2 @ 40 Step 3 @ 12 Step 4@ 16 Step 5@20 A. 5 min B. 1.8 min C. 3 min D. 2 min Step 2= bottleneck Takt time= 2 min --D Takt = Net operating time per period / customer demand Net operating Time= 60 min per hour Customer demand = 30 unit/ hour
Company struggling with low performance in terms of quality, profitability, and productivity is considering a six sigma initiative. Decision to proceed would be considered: A. Smart, lot of low-lying fruit B. Unwise, probably can't afford the effort C. Unwise, they need to attend to basic activities first D. Smart, they have obviously need the six sigma structure
Company struggling with low performance in terms of quality, profitability, and productivity is considering a six sigma initiative. Decision to proceed would be considered: A. Smart, lot of low-lying fruit B. Unwise, probably can't afford the effort C. Unwise, they need to attend to basic activities first D. Smart, they have obviously need the six sigma structure C- Correct
Concept behind PCDA is: 1) Deming/Shewart Cycle 2) Process Flow 3) Continuous Improvement 4) Satisfying suppliers
Concept behind PCDA is: 1) Deming/Shewart Cycle 2) Process Flow 3) Continuous Improvement 4) Satisfying suppliers 3--correct
Defect levels , as reported by Motorola, are higher than one might expect from use of a standard normal table or traditional capability calculations. Why is this true? A.Motorola found their processes followed the exponential distribution B. Motorola allowed fro failure on one-tail only c. Motorola allowed for a 1.5 sigma shift in the mean d. Motorola found that six sigma efforts increased process variation.
Defect levels , as reported by Motorola, are higher than one might expect from use of a standard normal table or traditional capability calculations. Why is this true? A.Motorola found their processes followed the exponential distribution B. Motorola allowed fro failure on one-tail only c. Motorola allowed for a 1.5 sigma shift in the mean d. Motorola found that six sigma efforts increased process variation. C-correct---used 1.5 standard devations to "safely"reort defect levels and process improvements
Difference between strategic quality goals and strategic business plans is that : A. Strategic quality goals are often a lower tier than the strategic business plan B. They are determined by top management only C. They may offer conflicting priorities d. They are based on priorities by all levels of the company.
Difference between strategic quality goals and strategic business plans is that : A. Strategic quality goals are often a lower tier than the strategic business plan B. They are determined by top management only C. They may offer conflicting priorities d. They are based on priorities by all levels of the company. A- correct---> Band D are common to both strategic quality goals and strategic business plan. C- wrong because strategic business plan forms the higher level with strategic quality goals being part of it.
FMEA authorities suggest that FMEA review should be composed of: A. Design engineer and one independent party B. 5-10 qualified team members C. Designer, producer, user D. 3-6 design engineers
FMEA authorities suggest that FMEA review should be composed of: A. Design engineer and one independent party B. 5-10 qualified team members C. Designer, producer, user D. 3-6 design engineers B- correct; III-36
FMEAS satisfy which of the following basic organizational needs? A. FMEAS are of little value since they are tedious B. Auditors will not hand out a finding if FMEAs are in compliance C. Bottom line is automatically improved D. Risk of quality defects is greatly reduced
FMEAS satisfy which of the following basic organizational needs? A. FMEAS are of little value since they are tedious B. Auditors will not hand out a finding if FMEAs are in compliance C. Bottom line is automatically improved D. Risk of quality defects is greatly reduced D- correct
FMEAS satisfy which of the follwoing basic organizational needs A. FMEAS are the marginal value since they are very tedious B. Auditors will not hand out a finding if FMEAs are in compliance C. Bottom line is automatically improved D. The risk of defects can be greatly reduced by corrective action
FMEAS satisfy which of the follwoing basic organizational needs A. FMEAS are the marginal value since they are very tedious B. Auditors will not hand out a finding if FMEAs are in compliance C. Bottom line is automatically improved D. The risk of defects can be greatly reduced by corrective action D- correct; Auditors must verify that FMEAS are completed and are in compliance.
From an upper management perspective, what has been the principal motivating factor in embracing six sigma? A. Bottom line results B. Market share growth C. Defect Reductions D. Customer Focus
From an upper management perspective, what has been the principal motivating factor in embracing six sigma? A. Bottom line results B. Market share growth C. Defect Reductions D. Customer Focus A= correct ---> Crosby one stated that upper management is interested in money.
Goldratt's theory of constraints deals with money in relationship to 3 fundamental measurements for evaluating system. Align the following measures with their monetary equivalents A. Throughput equals money going out B. Inventory equals money stuck inside C. Operational expenses equals money coming in D. Throughput equal money stuck inside
Goldratt's theory of constraints deals with money in relationship to 3 fundamental measurements for evaluating system. Align the following measures with their monetary equivalents A. Throughput equals money going out B. Inventory equals money stuck inside C. Operational expenses equals money coming in D. Throughput equal money stuck inside B- correct (Section II/ 15-16_
How many non-alue added activities are classified as muda by Imai? A. 4 B. 5 C. 7 D. 9
How many non-alue added activities are classified as muda by Imai? A. 4 B. 5 C. 7 D. 9 C- correct. 7 categories of waste: overproduction, inventory, rejects, motion, additional processing, waiting, & transport
How many of the following Japanese techniques are supportive of operational control? A. Poke-yoke, gemba, 5S, muda b. Poke-yoke and 5S, muda c. TPM, gemba, kanban, 5S d. kanban, poka-yoke, 5s, TPM
How many of the following Japanese techniques are supportive of operational control? A. Poke-yoke, gemba, 5S, muda b. Poke-yoke and 5S, muda c. TPM, gemba, kanban, 5S d. kanban, poka-yoke, 5s, TPM D- Correct--- Poke-yoke controls mistakes, 5S controls organizations, TPM control machines maintenance, Kanban controls workflow.
Identify 2 lean techniques that often used interchangeably: A. Motion study and JIT principles B. SMED and SUR C. TPM and visual displays D. 5S systems and NVA activities
Identify 2 lean techniques that often used interchangeably: A. Motion study and JIT principles B. SMED and SUR C. TPM and visual displays D. 5S systems and NVA activities B-correct ; SUR- setup reduction
Identify a Non-value added activity that wold be considered a form of processing muda? A. All forms of transportation B. Ergonomically unsound workplace C. Reshaping a product due to poor dies D. Producing more than needed by the customer
Identify a Non-value added activity that wold be considered a form of processing muda? A. All forms of transportation B. Ergonomically unsound workplace C. Reshaping a product due to poor dies D. Producing more than needed by the customer C==Correct; D is overproduction muda, B=motion muda; A- transportation muda
Identify the business element that would directly reduce cycle times? a. Utilizing Problem Solving Tools B. Implementing 5S C. Practicing SMED D. Supervising people
Identify the business element that would directly reduce cycle times? a. Utilizing Problem Solving Tools B. Implementing 5S C. Practicing SMED D. Supervising people C- Correct; SMED= single minute exchange dies
Identify the element that is associated with excess inventory? A. Storage space and transportation vehicles B. Machine downtime and lack of parts C. Repair and rework D. Poke-yoka devices
Identify the element that is associated with excess inventory? A. Storage space and transportation vehicles B. Machine downtime and lack of parts C. Repair and rework D. Poke-yoka devices A- Correct; (B) - muda of waiting; (C)= muda of rework
Identify the most difficult limitation in achieving continuous flow: A. untrained employees B. existing equipment C. Employee culture D. Middle management involvement
Identify the most difficult limitation in achieving continuous flow: A. untrained employees B. existing equipment C. Employee culture D. Middle management involvement B- correct---All choice except existing equipment can be changed by training and management
If a company were to evaluate why some customer refused to purchase a newly released product, what Deming cycle phase would apply? A. Plan B. Do C. Study D. Act
If a company were to evaluate why some customer refused to purchase a newly released product, what Deming cycle phase would apply? A. Plan B. Do C. Study D. Act C-correct
If a metric were being developed to track marketplace response, which of the following items could be included? A. Cost of quality B. Customer retention C. Cycle time reduction D. Profit margin on sales
If a metric were being developed to track marketplace response, which of the following items could be included? A. Cost of quality <0----measure of resource allocation B. Customer retention --Correct C. Cycle time reduction 0---measure of cost or internal resources. D. Profit margin on sales ---measure of profit B-answer
If metrics were used to track marketplace response as part of strategic plan deployment, which of the following measures is unlikely to be included? A. Analysis of Returns B. Cost of Quality C. Customer market surveys D. Customer Retention
If metrics were used to track marketplace response as part of strategic plan deployment, which of the following measures is unlikely to be included? A. Analysis of Returns B. Cost of Quality C. Customer market surveys D. Customer Retention B- correct---> Bis a resource measurement (Section II 35-36)
If one chose to look at any business on a mail level basis, which of following categores would be inegrated into other KPIC AND KPOV AREAS? A. process B. Operations C. Business D. Technological
If one chose to look at any business on a mail level basis, which of following categores would be inegrated into other KPIC AND KPOV AREAS? A. process B. Operations C. Business D. Technological D- Correct. --All other answers have key input and output variables---> D is not separately identified and is integrated into 3 categories Section II -34/41
In a new product design, the "fuzzy front end" refers to: A. Idea generation and sorting idea B. Sorting of ideas and concepts C. conducting feasibility studies D. Continuous learning techniques
In a new product design, the "fuzzy front end" refers to: A. Idea generation and sorting idea B. Sorting of ideas and concepts C. conducting feasibility studies D. Continuous learning techniques A- Correct (Section III-21) and XI-page 4
In a nutshell, six sigma is considered: A. Business improvement approach B. Focus on critical customer items C. Elimination of mistakes and defect D. Concentrated focus on business outputs.
In a nutshell, six sigma is considered: A. Business improvement approach B. Focus on critical customer items C. Elimination of mistakes and defect D. Concentrated focus on business outputs. A= best answer
In a production factory, which utilizes the pull system, which of the following may be achieved? A. Expand raw material inventory B. Reduced in-process inventory C. Increased prices D. Increased finished good inventory
In a production factory, which utilizes the pull system, which of the following may be achieved? A. Expand raw material inventory B. Reduced in-process inventory C. Increased prices D. Increased finished good inventory B- correct; Pull system is driven by customer demand; Stabilized prizes and increased profits can be achieved
In highly effective six sigma companies, most employee receive some training. What group is most likely to receive sponsorship training? A. Senior management B. Master belt C. Black Belt D. Green belt
In highly effective six sigma companies, most employee receive some training. What group is most likely to receive sponsorship training? A. Senior management B. Master belt C. Black Belt D. Green belt A. ---correct
In the long run, who/what defines the value of a product or service? A. Customer B. Upper management C. Cost and related expenses D. Amount of accrued muda
In the long run, who/what defines the value of a product or service? A. Customer B. Upper management C. Cost and related expenses D. Amount of accrued muda A- Correct
In what areas would upper management be most helpful in the initiation of 6 sigma effort. A. Providing direct training to black belts B.Standardizing business operations C. Providing key resources to the organization D. Directing the improvement projects
In what areas would upper management be most helpful in the initiation of 6 sigma effort. A. Providing direct training to black belts B.Standardizing business operations C. Providing key resources to the organization D. Directing the improvement projects C= correct---Upper management functions best by providing overall direction and resources. Section 11- pg 16
Increasing a performance in 6sigma corporation from 3 sigma to 4 sigma would reduce DPM by a factor of A. 2 B. 8 C. 10 D. 16
Increasing a performance in 6sigma corporation from 3 sigma to 4 sigma would reduce DPM by a factor of A. 2 B. 8 C. 10 D. 16 C= correct---> Since 6sigma is referenece, then assume that +/- 1.5 sigma must be included. Using the shift, the 4 sigma defect rate is 6,210 ppm and 3 sigma rate is 66,810 ppm or a ratio of 1: 10.76 Section II-3
Kaplan and Norton have outlined a business planning process that gives consideration to factors other than strictly financial ones. It provides a greater perspective to the stakeholder interest. This approach is referred to as: A. Balanced Scorecard B. Strategic Planning C. Fiver Forces of Competitive Strategy D. Quality Function Deployment
Kaplan and Norton have outlined a business planning process that gives consideration to factors other than strictly financial ones. It provides a greater perspective to the stakeholder interest. This approach is referred to as: A. Balanced Scorecard B. Strategic Planning C. Five Forces of Competitive Strategy D. Quality Function Deployment Answer= A--balanced scorecard QFD is the House of Quality
Lean enterprise can be summarized as: A. Enterprise organization involved with improvement B. Implementation of SMED cycle time techniques C. Poke-yoke techniques in action D. Ergonomic principles in the workplace
Lean enterprise can be summarized as: A. Enterprise organization involved with improvement B. Implementation of SMED cycle time techniques C. Poke-yoke techniques in action D. Ergonomic principles in the workplace A- Correct
Metrics of the effectiveness of strategic quality plan include" A. DMAIC B. Customer Satisfaction C. CSI number D. Drennik index
Metrics of the effectiveness of strategic quality plan include" A. DMAIC B. Customer Satisfaction C. CSI number D. Drennik index B--correct---> Customer satisfaction, customer retention, warranty claims, number of completed quality project teams are all strategic metrics. CSI can be customer satifaction index or crimse scene investigation. D- madeup
Modifying or Redesigning a product would most likely occur during which two of the PDCA phases A. Plan and Do B. Check and Act C. Do and Act D. Plan and Act
Modifying or Redesigning a product would most likely occur during which two of the PDCA phases A. Plan and Do B. Check and Act C. Do and Act D. Plan and Act C= correct ---> Question suggest that actual work on the design on the design is takin gplace.
Most important element in six sigma deployment is considered: A. Training B. Organizational Structure C. Management Support D. Reward and Recognizition
Most important element in six sigma deployment is considered: A. Training B. Organizational Structure C. Management Support D. Reward and Recognisition Answer C= All of the answer choices are key six sigma elements. However, the question states the "most important element". All other choices can be provided or adjusted if management support is there
Most significant difference between the six step DMADOV design process and the 4 step IDOV design process: A) 2 additional design steps in the DMADOV process B) IDOV uses validate and DMODOV uses verify C) IDOV process is quicker D) IDOV includes measure and analyze in the design step
Most significant difference between the six step DMADOV design process and the 4 step IDOV design process: A) 2 additional design steps in the DMADOV process B) IDOV uses validate and DMODOV uses verify C) IDOV process is quicker D) IDOV includes measure and analyze in the design step D-correct ---A and B are true but not significant. IDOV combines the measure step into identify and design step and also include the analyze step with the design step ( III--pg 25/26)
Non-value added activities on the factor floor are most clearly controlled by elimination of: A. Gemba B. Muda C. Poka-Yoka D. Kaizen
Non-value added activities on the factor floor are most clearly controlled by elimination of: A. Gemba B. Muda C. Poka-Yoka D. Kaizen B- correct; Gemba means factor floor; Kaizen means good change
Of the key elements of an organizational plan, which of the following would be most likely to contain numbers and dates? A. Vision statement B. Tactical objectives C. Guiding principles D. Mission statement
Of the key elements of an organizational plan, which of the following would be most likely to contain numbers and dates? A. Vision statement B. Tactical objectives C. Guiding principles D. Mission statement B--correct because all goals should be quantifiable and measurable
One of Deming's 14 points of management states "Cease dependence upon inspection as a way to achieve quality" means: A. Many American companies employ too many inspectors B. Quality should be built into the product, not inpected in C. In most case, the worker should perform his own inspection and not rely on someone else. D. Most manual inpsection will miss 10%-20% of defects under typical working conditions.
One of Deming's 14 points of management states "Cease dependence upon inspection as a way to achieve quality" means: A. Many American companies employ too many inspectors B. Quality should be built into the product, not inpected in C. In most case, the worker should perform his own inspection and not rely on someone else. D. Most manual inpsection will miss 10%-20% of defects under typical working conditions. B-correct
One would suspect that process FMEA would result from: A. Studying the manufacturing and assembly process B. Interaction between the systems, subsystems and components C. Investigating the function requirements and design alternatives D. Review on failure modes before the first service
One would suspect that process FMEA would result from: A. Studying the manufacturing and assembly process B. Interaction between the systems, subsystems and components C. Investigating the function requirements and design alternatives D. Review on failure modes before the first service A- correct B= system FMEA; C = Design FMEA D= Service FMEA
One would that continuous flow manufacturing" a. Increases product damage b. Requires more storage and transport c. Reduces cycle times d. Solves most other production problems
One would that continuous flow manufacturing" a. Increases product damage b. Requires more storage and transport c. Reduces cycle times d. Solves most other production problems C-correct---Little law--Inventory= Flow time X Flow rate Seciton III 6/11
Process FMEA is generally performed A. Just after design FMEA B. Just before the production tool is authorized C. Just after the design drawings are finalized D. As soon as the manufacturing defect is uncovered
Process FMEA is generally performed A. Just after design FMEA B. Just before the production tool is authorized C. Just after the design drawings are finalized D. As soon as the manufacturing defect is uncovered B-correct. Process FMEA is initiated before or after the feasibility stage, prior to production tooling, and accounts for all manufacturing operations. A and C are partially correct, in that PFMEA is started after the DFMEA but it could be some time befor production acitivies start up. PFMEA should be before manufacturing commences.
Quality guru who believed the best approach to understanding the purpose of quality system would be the absolutes of Quality management? A. Feigenbaum B. Crosby C. Deming D. Juran
Quality guru who believed the best approach to understanding the purpose of quality system would be the absolutes of Quality management? A. Feigenbaum B. Crosby C. Deming D. Juran B-correct---> Croby's 4 absolutes of quality management
RPN is the measure of the risk of a failure mode. The ratings are on a 1-10 scale. If FMEA has 10 failure modes with RPN of 50 to 300, improvement team should focus on which of the following? A. Work on those failures with RPNs greater than 50 B. Use the Pareto principle to prioritize highest RPNs C. Identify failure modes with high severity rankings, followed by high RPN D. Use the Pareto principle and start with top 20% of the failure modes.
RPN is the measure of the risk of a failure mode. The ratings are on a 1-10 scale. If FMEA has 10 failure modes with RPN of 50 to 300, improvement team should focus on which of the following? A. Work on those failures with RPNs greater than 50 B. Use the Pareto principle to prioritize highest RPNs C. Identify failure modes with high severity rankings, followed by high RPN D. Use the Pareto principle and start with top 20% of the failure modes. C- correct --III-pg 30
Short-term tactical plans are defined by: A. Defined by Customer B. Set before objectives can be determined C. Supportive of strategic objectives D. Normally opposite of long range objectives.
Short-term tactical plans are defined by: A. Defined by Customer B. Set before objectives can be determined C. Supportive of strategic objectives D. Normally opposite of long range objectives. C is correct! ---Short-term tactical plans or operational plans are used in implement long and short-term strategic plans. Functional departments, develop short-term objectives, budgets, policies, and programs to support the organizations' strategic plans. Short-term plans may be developed to satisfy customer needs, but are not defined by the custoerm. Therefore, A= incorrect. B= wrong--->objectives must be defined before the plans to meet those objectives can be determined. D= false---both short and long-term quality plans should support strategic objectives
Six Sigma project benefits should include which of the following? A. Reduced profits B. Improved process capability C. Increased Defects D. Delayed warranty claims
Six Sigma project benefits should include which of the following? A. Reduced profits B. Improved process capability C. Increased Defects D. Delayed warranty claims B---correct
Strategic goals must be subdivided. Thus , they are: A. Delegated B. Distributed C. Accountable D. Deployed
Strategic goals must be subdivided. Thus , they are: A. Delegated---> Assigned goals B. Distributed C. Accountable D. Deployed---> goals are spread out into attainable portions. D-correct
Strategic plan implementation at the function level requires: A. Functional level metrics B. Company quality policy with everyone understanding it C. Functional short and long-term strategic goals D. Customer Focus
Strategic plan implementation at the function level requires: A. Functional level metrics B. Company quality policy with everyone understanding it C. Functional short and long-term strategic goals D. Customer Focus C= correct ( section II- 37/41)
Strategic quality goals are subdivided into: A. Major benchmarks B. Loss Functions C. Number tactical quality goals D. Appropriate Metrics
Strategic quality goals are subdivided into: A. Major benchmarks B. Loss Functions C. Number tactical quality goals D. Appropriate Metrics C= Correct (Section II-37) Strategic quality goals must be moved down to the lower levels of the organization via some technique. The rest are not deployment techniques
Term "metric" refers to: A. Unit of measurement B. Metric system c. Science or weights and meaurements D. Evaluation method
Term "metric" refers to: A. Unit of measurement B. Metric system c. Science or weights and meaurements D. Evaluation method C-correct
The most effective and efficient method of solving quality problems for a product is to concentrate efforts in the area: A. Design B. Production c. Quality improvement D. Lean techniques.
The most effective and efficient method of solving quality problems for a product is to concentrate efforts in the area: A. Design B. Production c. Quality improvement D. Lean techniques. A- correct---It has been stated that 80% of the qulity problems are desing related. Given this fact, the best option is prevent
The results of lean principles/ thinking transformation show the greatest reduction in the areas of : A. Throughput times and inventories B. Customer errors and in -house scrap C. Safety injuries and capital investment D. Productivity and injury areas
The results of lean principles/ thinking transformation show the greatest reduction in the areas of : A. Throughput times and inventories B. Customer errors and in -house scrap C. Safety injuries and capital investment D. Productivity and injury areas A- correct; there in increase in productivity; 90% reduction in Throughput times and inventories. 50% reduction in customer errors, in-house scrap, injuries, and product development times .
The term severity in FMEA describes: A. Difficulty completing the FMEA form B. Possible impact to a system user of failure C. Likilihood of failure D. Time for which the system is expected to be down
The term severity in FMEA describes: A. Difficulty completing the FMEA form B. Possible impact to a system user of failure C. Likilihood of failure D. Time for which the system is expected to be down C- Correct
Theory of Constraints concentrates mainly on" A. Understanding customer needs B. Developing value stream map C. Achieving on-time goals D. Removing process bottlenecks
Theory of Constraints concentrates mainly on" A. Understanding customer needs B. Developing value stream map C. Achieving on-time goals D. Removing process bottlenecks D-correct
Upon completion of FMEA. what critical even should be established next? A. Ensure that process owner is in charge of FMEA B. Designate engineer to follow-up on recommended actions C. Review documents at regularly scheduled intervals D. Have Cross-functional team assigned to each FMEA to review activities
Upon completion of FMEA. what critical even should be established next? A. Ensure that process owner is in charge of FMEA B. Designate engineer to follow-up on recommended actions C. Review documents at regularly scheduled intervals D. Have Cross-functional team assigned to each FMEA to review activities A- correct--project ownership is turned over to the project owner after the consultants are done
Using Six sigma, a company with 4.5 sigma will have a failure rate of: A. 3.4 ppm B. 233 ppm C. 1350 ppm D. 6210 ppm
Using Six sigma, a company with 4.5 sigma will have a failure rate of: A. 3.4 ppm B. 233 ppm C. 1350 ppm D. 6210 ppm C-correct; D= 4 sigma levelsl B- 5 sigma level
Using the PDCA process to design a customer survey, while implementing a customer feedback and improvement process is an example of: A. Critical path method B. Customer driven company C. PDCA process within a PDCA process D. Reactive verses a proactive approach
Using the PDCA process to design a customer survey, while implementing a customer feedback and improvement process is an example of: A. Critical path method B. Customer driven company C. PDCA process within a PDCA process D. Reactive verses a proactive approach C= correct ----> Section II--27/28
What design structure uses the following 4 main phases in the design process? . Clarify the task, Develop conceptual design, Refine design, Generate final detailed design A. Set-based design B. Pugh Analysis C. Critical parameter design D. Systemic Design
What design structure uses the following 4 main phases in the design process? . Clarify the task, Develop conceptual design, Refine design, Generate final detailed design A. Set-based design B. Pugh Analysis C. Critical parameter design D. Systemic Design D- correct---See Primer Section III-28
What is the best reason for having relatively few strategic objectives or goals? A. Difficulties in deploying them horizontally and vertically b. Potential for confusion among employees as to their relative importance c. Problems associated with monitoring and adjusting them properly d. Potential for organizational administration barriers
What is the best reason for having relatively few strategic objectives or goals? A. Difficulties in deploying them horizontally and vertically b. Potential for confusion among employees as to their relative importance c. Problems associated with monitoring and adjusting them properly d. Potential for organizational administration barriers B- correct
What is the biggest risk when developing a product FMEA/ FMEACA? A. Inadequate recommended corrective actions B. Unknown current controls C. Overlooked potential failure modes D. Inadequate number of assigned engineers
What is the biggest risk when developing a product FMEA/ FMEACA? A. Inadequate recommended corrective actions B. Unknown current controls C. Overlooked potential failure modes D. Inadequate number of assigned engineers C- correct
What is the definition of Takt time? A. it is calculated time element that equals customer demand B. Speed at which parts must be manufactured in order to satisfy demand C. Heartbeat of any lean system D. Application of Kaizen to continuous flow manufacturing
What is the definition of Takt time? A. it is calculated time element that equals customer demand B. Speed at which parts must be manufactured in order to satisfy demand C. Heartbeat of any lean system D. Application of Kaizen to continuous flow manufacturing A- correct
What is value stream? A. Elimination or reductoin of internal waste B. Minimization of internal, hidden muda C. Map identifying all product related activities D. Value as perceived by the customer
What is value stream? A. Elimination or reductoin of internal waste B. Minimization of internal, hidden muda C. Map identifying all product related activities D. Value as perceived by the customer C- Correct
What two organizational steps typically provide feedback to business systems and processes? A. Customer and outputs B. Suppliers and inputs C. Inputs and Outputs D. Outputs and Suppliers
What two organizational steps typically provide feedback to business systems and processes? A. Customer and outputs B. Suppliers and inputs C. Inputs and Outputs D. Outputs and Suppliers A= Correct---> Normally feedback from areas downstream from the business processes. The typical feedback sources are outputs and customers. (Section II-9)
What would occur if quality goals were not part of the strategic plan ? A. No strategic goals would exist B. Not much emphasis on quality C. Total quality effort would not suffer D. Quality Department would still maintain the quality goals
What would occur if quality goals were not part of the strategic plan ? A. No strategic goals would exist B. Not much emphasis on quality C. Total quality effort would not suffer D. Quality Department would still maintain the quality goals B- correct---. Strategic goals could exist without a quality element. D is wrong beacaue quality goals are not strategic in nature.
When a pull system is instituted within an organization, which of the following is stabilized? A. Finished good inventories B. Work-in-progress C. Cycle times D. Pricing
When a pull system is instituted within an organization, which of the following is stabilized? A. Finished good inventories B. Work-in-progress C. Cycle times D. Pricing D- Correct;Key word is stabilized; Generally WIP and finished goods are reduced and cycle times are decreased Customer orders and pricing are stabilized Section III-7
When assess the probability of failure of a product or a system component an index value of 9 is assigned. This means? A. Severity of the failure is high B. High probability of failure c. Control effectiveness is very good D. Over RPN is huge
When assess the probability of failure of a product or a system component an index value of 9 is assigned. This means? A. Severity of the failure is high B. High probability of failure c. Control effectiveness is very good D. Over RPN is huge C- correct; A and C describe the severity and control effectiveness components of RPN
When comparing push verses pull concepts, who or what is really doing the pushing? A. Customer B. Cycle Time C. Company management D. Takt time
When comparing push verses pull concepts, who or what is really doing the pushing? A. Customer B. Cycle Time C. Company management D. Takt time C-correct; Push concept is associated with management maximizing production output
When setting quality department short-term objectives, the most important factor to consider is that: A. Short-term objectives address all improvement opportunities B. Departmental objectives include completion dates C. Milestones are established for each objective D. Quality objectives support the organizational objectives
When setting quality department short-term objectives, the most important factor to consider is that: A. Short-term objectives address all improvement opportunities B. Departmental objectives include completion dates C. Milestones are established for each objective D. Quality objectives support the organizational objectives D= correct When establishing departmental objectives, the most important factor is that they support the organizational objectives. Resources for completion of the departmental objectives would then be easier to obtain, and when completed, the organization will have made progress toward completing its objectives. Well constructed objectives do include completion dates and measures of achievement, but they are not the most important factors in the wording of this question . Section II-37
Which DMAIC is where root cause is found?
Which DMAIC is where root cause is found? Analysis
Which of following quality liminaries would be most clearly identified as a proponent of improvement and breakthrough projects? A. Ishikawa B. Deming C. Juran D. Crosby
Which of following quality luminaries would be most clearly identified as a proponent of improvement and breakthrough projects? A. Ishikawa B. Deming C. Juran D. Crosby C- Correct---Quality improvement phase would be considered a project approach to improvement Juran Trilogy has 3 processes---Quality planning, Quality control and quality improvement
Which of the following are DFSS techniques? A. IDOV and DMADV B. Kaizen and Kanban C. SPC and CWQC D. DPIV and KPOV
Which of the following are DFSS techniques? A. IDOV and DMADV B. Kaizen and Kanban C. SPC and CWQC D. DPIV and KPOV A- correct ( Section III page 25/26)
Which of the following are defect elimination and detection techniques? A. Vendor certificate compliance B. Standard work and TPM C. Source Inspection and Operator self checks D. Non-value added activities and TOC
Which of the following are defect elimination and detection techniques? A. Vendor certificate compliance B. Standard work and TPM C. Source Inspection and Operator self checks D. Non-value added activities and TOC C- correct
Which of the following are value added activities? A. Mistaking proofing a process B. Transporting parts quickly C. Having extra inventory to meet customer demands d. Efficient internal repair processes
Which of the following are value added activities? A. Mistaking proofing a process B. Transporting parts quickly C. Having extra inventory to meet customer demands d. Efficient internal repair processes A- correct--"do things right the first time"
Which of the following conditions are driving companies to adopt a lean approach? a. Fixed performance requirements b. Eliminating waste from the process C. Increasing total costs D. Decreasing capacity
Which of the following conditions are driving companies to adopt a lean approach? a. Fixed performance requirements b. Eliminating waste from the process C. Increasing total costs D. Decreasing capacity B- correct (section III- 2/10) ; the opposite are true for C and D
Which of the following forms of muda affects people more than product quality? a. Overproduction b. Excess Inventory c. Waiting d. Transport
Which of the following forms of muda affects people more than product quality? a. Overproduction b. Excess Inventory c. Waiting d. Transport C- correct
Which of the following is a measure of marketplace response? A. Customer Courtesy ratings B. Cost of Quality C. Percentage of defects generated D. Reduction in product or service Variation
Which of the following is a measure of marketplace response? A. Customer Courtesy ratings B. Cost of Quality C. Percentage of defects generated D. Reduction in product or service Variation A= Correct......Remaining are measurement of resource usage
Which of the following is an acceptable reason for the deployment of 6 sigma projects? A. Focus on costs savings and customer satisfaction B. Focus on quality planning, control, and improvement C. Focus on PDCA/ PDSA cyle D. Focus on Design Improvements
Which of the following is an acceptable reason for the deployment of 6 sigma projects? A. Focus on costs savings and customer satisfaction B. Focus on quality planning, control, and improvement C. Focus on PDCA/ PDSA cyle D. Focus on Design Improvements A= correct B= Juran's triology and C describes a problem-solving approach
Which of the following is considered muda? A. Design reviews B. Level scheduling of work C. Checking a die before installation D. Breakdowns in machinery
Which of the following is considered muda? A. Design reviews B. Level scheduling of work C. Checking a die before installation D. Breakdowns in machinery A- correct---> Design reviews are part of continuous improvement and are part of value-added activity
Which of the following is preventative technique? A. Rework due to poor molding B. Performing design validation C. In-process inspection D. Re-tooling because of engineering changes
Which of the following is preventative technique? A. Rework due to poor molding B. Performing design validation C. In-process inspection D. Re-tooling because of engineering changes B- correct; Other answers are forms of muda
Which of the following is the most necessary resource requirement needed to achieve strategic goals? a. Infrastructure and support of the projects b. Large training department c. Administration of programs d. Few tactical supporting goals
Which of the following is the most necessary resource requirement needed to achieve strategic goals? a. Infrastructure and support of the projects b. Large training department c. Administration of programs d. Few tactical supporting goals A-correct 0---section ii pag 6/9
Which of the following organizations is ready for DFSS approach? a. Organization has recently become ISO 9001 certified b. First full-time black belt was recently hired and oriented with the organization c. After many successful six sigma projects the rate of improvement has slowed d. New CEO has strong engineering background and wants change
Which of the following organizations is ready for DFSS approach? a. Organization has recently become ISO 9001 certified b. First full-time black belt was recently hired and oriented with the organization c. After many successful six sigma projects the rate of improvement has slowed d. New CEO has strong engineering background and wants change C- Correct-- ISO 9001, or other quality system certification (answer A) provides evidence of decent level of quality organization but it does not say anything about improvement projects and current quality levels
Which of the following statements can factually be made regarding the objective " Quality will be improved next year"? A. It describe the measure of quality B. This statement has a defined ending date C. How the improvements will be made are stated. D. It is easy to determine the new quality level
Which of the following statements can factually be made regarding the objective " Quality will be improved next year"? A. It describe the measure of quality B. This statement has a defined ending date C. How the improvements will be made are stated. D. It is easy to determine the new quality level B- correct!
Which of the following would be a device associated with visual factory? A. Standard work B. Andon board C. Queue time D. Work Cell
Which of the following would be a device associated with visual factory? A. Standard work B. Andon board C. Queue time D. Work Cell B- correct
Which of the following would be considered a strategic quality goal? A. Commitment to customer B. Reducing the scrap rate in the finishing department by 1% C. Improved performance inspection check on work in process. D. Training 6 green belts in statistical techniques this quarter
Which of the following would be considered a strategic quality goal? A. Commitment to customer B. Reducing the scrap rate in the finishing department by 1% C. Improved performance inspection check on work in process. D. Training 6 green belts in statistical techniques this quarter A- Correct---Key being Quality
Which six sigma steps comes last? A. Define project goals and customer needs specification B. Analyze the process options C. Verify and validate design D. Develop design details for producing customer needs
Which six sigma steps comes last? A. Define project goals and customer needs specification B. Analyze the process options C. Verify and validate design D. Develop design details for producing customer needs C- corrrect ; DMADV
Who coined the term Total Quality management? A. Feigenbaum B. Deming C. Juran D. Shewart
Who coined the term Total Quality management? A. Feigenbaum B. Deming C. Juran D. Shewart A---Feignebaum termed both TQM and TQC
Who is the creator of the control chart? A. Deming B. Shewart C. Juran D. Ishikawa
Who is the creator of the control chart? A. Deming B. Shewart C. Juran D. Ishikawa D=corect
Who was the creater of DOE? A. Deming B. Juran C. Ishikawa D. Taguchi
Who was the creater of DOE? A. Deming B. Juran C. Ishikawa D. Taguchi D= correct---> Taguchi presented a cook book approach
Why DFSS called future of six sigma? A. Few remaining DMAIC project available in most companies B. DFSS roadmaps are more attractive than DMAIC tools C. DFSS better serves the current innovation initiatives of many companies D. DMAIC project do not achieve six sigma levels without DFSS
Why DFSS called future of six sigma? A. Few remaining DMAIC project available in most companies B. DFSS roadmaps are more attractive than DMAIC tools C. DFSS better serves the current innovation initiatives of many companies D. DMAIC project do not achieve six sigma levels without DFSS C- Correct; In both private and govt sector express the need for whole strategies based on systematic innovation. DFSS roadmaps have the potential to become the center of such innovation initiatives. There are plenty of DMAIC projects in companies.
Why has six sigma been so successful for many organizations? A. Bottom line results are enhanced B. A +/- sigma shift is included C. An undisciplined approach is used D. Sound statistical approaches are eliminated
Why has six sigma been so successful for many organizations? A. Bottom line results are enhanced B. A +/- sigma shift is included C. An undisciplined approach is used D. Sound statistical approaches are eliminated A-correct
Why is PCDA more accepted by most American Teams? A. It is the natural way that most people already approach problmes b. It was promoted by an American, Deming C. Widely used in Japan with sucess D. Requires much less work than other improvement techniques
Why is PCDA more accepted by most American Teams? A. It is the natural way that most people already approach problmes b. It was promoted by an American, Deming C. Widely used in Japan with sucess D. Requires much less work than other improvement techniques A-correct
Why is six sigma called TQM on steriod? A. Because of the extensive training element requirement B. Because of the inclusion of statistical and lean tools C. Because of the heavy impact of top management support D. Because of the impact of cost savings on the bottom line.
Why is six sigma called TQM on steriod? A. Because of the extensive training element requirement B. Because of the inclusion of statistical and lean tools C. Because of the heavy impact of top management support D. Because of the impact of cost savings on the bottom line. B- Correct----> Steriod quote comes from the inclusion of statistical items such DOE, DFSS, statistical analysis, ect. and certain maufacturing tools
Womack stated that perfection in a lean organization should be: A. Specified b. Pursued C. Identified D. Pulled
Womack stated that perfection in a lean organization should be: A. Specified b. Pursued C. Identified D. Pulled B- Correct
A risk priority number indicates a more sever risk when it: A. It equals zero B. Value is lower C. Value is higher D. Value is indeterminate
A risk priority number indicates a more sever risk when it: A. It equals zero B. Value is lower C. Value is higher D. Value is indeterminate C- Correct
A team would be operating in which pahse of the Shewart cycle if they were conducting a pilot program test activity? A. Plan B. Act C. Check D. Do
A team would be operating in which phase of the Shewart cycle if they were conducting a pilot program test activity? A. Plan B. Act C. Check D. Do D= correct answer. )Section II-27-28 Studying the results of the pilot test to determine the next action would be in the Act phase. Carrying out the piolot detest of the idea is Do phase
According to Pande, which of the following is a legitimate reason for embracing a Six Sigma effort? A. The company currently has an effective improvement effort. B. Current changes are overwhelming the company resources C. Potential gains aren't sufficient to fund six sigma D. There are difficulties in meeting customer requirements
According to Pande, which of the following is a legitimate reason for embracing a Six Sigma effort? A. The company currently has an effective improvement effort. B. Current changes are overwhelming the company resources C. Potential gains aren't sufficient to fund six sigma D. There are difficulties in meeting customer requirements Answer= D Explanation = Pande suggest that answers A, B, and C are valid reasons to not undertake six sigma improvement Answer D is correct.
According to Womack, the most important LEAN principle is : A. Pursue Quality B. Make Value flow C. Pursue cost reduction D. Satisfy customers
According to Womack, the most important LEAN principle is : A. Pursue Quality B. Make Value flow C. Pursue cost reduction D. Satisfy customers B- Correct (seciton III; pg 2-3) ---> Womak and guiding principles of LEAN thinking
After the development of a viable corporate strategy, the next logical step would be: A. PDCA B. Deployment C.SWOT D. Benchmarking
After the development of a viable corporate strategy, the next logical step would be: A. PDCA B. Deployment C.SWOT D. Benchmarking B-correct---SWOT and benchmarking occurs before strategy development. PDCA is problem solving tool that is off target with direction . Deployment is after the strategy development
An advantage of training managers in six sigma concepts before improvement team member is ? A. Managers have more time available for training B. Managers must lead the deployment of six sigma C. Managers must understand the concepts better than the team member D. Manager must pay for worker training
An advantage of training managers in six sigma concepts before improvement team member is ? A. Managers have more time available for training B. Managers must lead the deployment of six sigma C. Managers must understand the concepts better than the team member D. Manager must pay for worker training B-correct
