Deck 1

Question 1

What is the primary goal of Lean Six Sigma?
a) To increase variation in processes.
b) To eliminate waste in processes.
c) To reduce customer satisfaction.
d) To increase defects in products.

Answer 1

b) To eliminate waste in processes.

Question 2

What is the DMAIC methodology used in Lean Six Sigma?
a) Define, Measure, Analyze, Improve, Control.
b) Develop, Monitor, Assess, Implement, Check.
c) Determine, Manage, Align, Implement, Coordinate.
d) Delegate, Measure, Adapt, Implement, Control.

Answer 2

a) Define, Measure, Analyze, Improve, Control.

Question 3

What is the purpose of the Define phase in DMAIC?
a) To define the problem and scope of the project.
b) To collect data and establish a baseline performance.
c) To identify the root causes of the problem.
d) To generate and implement solutions.

Answer 3

a) To define the problem and scope of the project.

Question 4

What is the difference between a defect and a defect opportunity in Six Sigma?
a) A defect is a chance for a defect to occur, while a defect opportunity is a failure to meet customer requirements.
b) A defect is a failure to meet customer requirements, while a defect opportunity is a chance for a defect to occur.
c) A defect and a defect opportunity are the same thing.
d) A defect and a defect opportunity are irrelevant in Six Sigma.

Answer 4

b) A defect is a failure to meet customer requirements, while a defect opportunity is a chance for a defect to occur.

Question 5

What is the formula for calculating defect per million opportunities (DPMO)?
a) DPMO = (Number of Defects / Number of Units) x 1,000,000.
b) DPMO = Number of Defects x 1,000,000.
c) DPMO = (Number of Opportunities / Number of Defects) x 1,000,000.
d) DPMO = (Number of Units / Number of Defects) x 1,000,000.

Answer 5

a) DPMO = (Number of Defects / Number of Units) x 1,000,000.

Question 6

What is the purpose of a process map in Lean Six Sigma?
a) To visualize and understand the steps and flow of a process.
b) To identify the root causes of a problem.
c) To monitor and control process stability and variation.
d) To track the performance of a process over time.

Answer 6

a) To visualize and understand the steps and flow of a process.

Question 7

What is the key principle of the 5S methodology in Lean?
a) Sort, Set in Order, Shine, Standardize, Sustain.
b) Solve, Study, Standardize, Support, Sustain.
c) Sort, Streamline, Standardize, Support, Sustain.
d) Speed up, Simplify, Standardize, Support, Sustain.

Answer 7

a) Sort, Set in Order, Shine, Standardize, Sustain.

Question 8

What is the main objective of the Measure phase in DMAIC?
a) To define the problem and scope of the project.
b) To collect data and establish a baseline performance.
c) To identify the root causes of the problem.
d) To generate and implement solutions.

Answer 8

b) To collect data and establish a baseline performance.

Question 9

What is the difference between Type I and Type II errors in hypothesis testing?
a) Type I error occurs when a null hypothesis is rejected incorrectly, while Type II error occurs when a null hypothesis is accepted incorrectly.
b) Type I error occurs when a null hypothesis is accepted incorrectly, while Type II error occurs when a null hypothesis is rejected incorrectly.
c) Type I and Type II errors are the same thing.
d) Type I and Type II errors are irrelevant in hypothesis testing.

Answer 9

a) Type I error occurs when a null hypothesis is rejected incorrectly, while Type II error occurs when a null hypothesis is accepted incorrectly.

Question 10

What is the purpose of a control chart in Lean Six Sigma?
a) To visualize and understand the steps and flow of a process.
b) To identify the root causes of a problem.
c) To monitor and control process stability and variation.
d) To track the performance of a process over time.

Answer 10

c) To monitor and control process stability and variation.

Question 11

What is a Kaizen event in Lean Six Sigma?
a) A focused and intensive improvement activity conducted within a short timeframe.
b) A long-term improvement project conducted by a team of experts.
c) A meeting to discuss project progress and challenges.
d) A formal presentation of project findings and recommendations.

Answer 11

a) A focused and intensive improvement activity conducted within a short timeframe.

Question 12

What is the concept of poka-yoke in Lean Six Sigma?
a) The use of mistake-proofing techniques to prevent errors and defects from occurring.
b) The use of statistical analysis to identify process improvement opportunities.
c) The application of control charts to monitor process performance.
d) The use of brainstorming sessions to generate innovative ideas.

Answer 12

a) The use of mistake-proofing techniques to prevent errors and defects from occurring.

Question 13

What is the formula for calculating process capability index (Cpk)?
a) Cpk = (USL - Mean) / (3 x Standard Deviation).
b) Cpk = (Mean - LSL) / (3 x Standard Deviation).
c) Cpk = (USL - LSL) / (6 x Standard Deviation).
d) Cpk = (Mean - USL) / (3 x Standard Deviation).

Answer 13

b) Cpk = (Mean - LSL) / (3 x Standard Deviation).

Question 14

What is the purpose of a fishbone diagram in problem-solving?
a) To visualize and understand the steps and flow of a process.
b) To identify the root causes of a problem.
c) To monitor and control process stability and variation.
d) To track the performance of a process over time.

Answer 14

b) To identify the root causes of a problem.

Question 15

What is the primary objective of the Analyze phase in DMAIC?
a) To define the problem and scope of the project.
b) To collect data and establish a baseline performance.
c) To identify the root causes of the problem.
d) To generate and implement solutions.

Answer 15

c) To identify the root causes of the problem.

Question 16

What is the difference between a continuous variable and a discrete variable in statistics?
a) A continuous variable can only take specific values, while a discrete variable can take any value within a range.
b) A continuous variable is qualitative, while a discrete variable is quantitative.
c) A continuous variable can take any value within a range, while a discrete variable can only take specific values.
d) A continuous variable and a discrete variable are the same thing.

Answer 16

c) A continuous variable can take any value within a range, while a discrete variable can only take specific values.

Question 17

What is the 80/20 rule, also known as the Pareto principle, in Lean Six Sigma?
a) It states that roughly 80% of the effects come from 20% of the causes.
b) It states that roughly 20% of the effects come from 80% of the causes.
c) It states that roughly 80% of the effects come from 80% of the causes.
d) It states that roughly 20% of the effects come from 20% of the causes.

Answer 17

a) It states that roughly 80% of the effects come from 20% of the causes.

Question 18

What is the purpose of a run chart in Lean Six Sigma?
a) To visualize and understand the steps and flow of a process.
b) To identify the root causes of a problem.
c) To monitor and control process stability and variation.
d) To track the performance of a process over time.

Answer 18

c) To monitor and control process stability and variation.

Question 19

What is the role of a Sponsor in Lean Six Sigma?
a) A Sponsor is a senior leader who supports and sponsors Lean Six Sigma initiatives within an organization.
b) A Sponsor is an individual who leads improvement projects and assists Black Belts in larger projects.
c) A Sponsor is an expert in Lean Six Sigma methodology who provides guidance and mentorship to Black Belts and Green Belts.
d) A Sponsor is responsible for collecting and analyzing data to drive process improvement.

Answer 19

a) A Sponsor is a senior leader who supports and sponsors Lean Six Sigma initiatives within an organization.

Question 20

What is the concept of benchmarking in Lean Six Sigma?
a) The process of comparing performance metrics against industry best practices or competitors.
b) The process of analyzing data to identify patterns and relationships.
c) The process of implementing and monitoring control charts.
d) The process of identifying and eliminating waste in a process.

Answer 20

a) The process of comparing performance metrics against industry best practices or competitors.

Question 21

What is the purpose of a failure mode and effects analysis (FMEA) in Lean Six Sigma?
a) To visualize and understand the steps and flow of a process.
b) To identify the root causes of a problem.
c) To assess the potential failure modes and their effects on a process.
d) To track the performance of a process over time.

Answer 21

c) To assess the potential failure modes and their effects on a process.

Question 22

What is the concept of lead time in Lean Six Sigma?
a) The time taken to complete a process step or task.
b) The time taken to produce a product from start to finish.
c) The time taken to respond to a customer request or order.
d) The time taken to implement process improvements.

Answer 22

b) The time taken to produce a product from start to finish.

Question 23

What is the purpose of a scatter plot in data analysis?
a) To examine the relationship between two variables and identify any correlation.
b) To identify the root causes of a problem.
c) To monitor and control process stability and variation.
d) To track the performance of a process over time.

Answer 23

a) To examine the relationship between two variables and identify any correlation.

Question 24

What is the primary goal of mistake-proofing in Lean Six Sigma?
a) To increase errors or defects in processes.
b) To prevent errors or defects from occurring or reaching the customer.
c) To introduce variability in processes.
d) To ignore the impact of errors or defects on customer satisfaction.

Answer 24

b) To prevent errors or defects from occurring or reaching the customer.

Question 25

What is the purpose of the Control phase in DMAIC?
a) To define the problem and scope of the project.
b) To collect data and establish a baseline performance.
c) To identify the root causes of the problem.
d) To ensure that the improvements are sustained and the process remains in control.

Answer 25

d) To ensure that the improvements are sustained and the process remains in control.

Question 26

What is the difference between nominal, ordinal, interval, and ratio scales of measurement?
a) Nominal scale categorizes data, ordinal scale ranks data, interval scale has equal intervals with no true zero, and ratio scale has equal intervals with a true zero.
b) Nominal scale ranks data, ordinal scale categorizes data, interval scale has equal intervals with no true zero, and ratio scale has equal intervals with a true zero.
c) Nominal scale categorizes data, ordinal scale has equal intervals with no true zero, interval scale ranks data, and ratio scale has equal intervals with a true zero.
d) Nominal scale ranks data, ordinal scale has equal intervals with no true zero, interval scale categorizes data, and ratio scale has equal intervals with a true zero.

Answer 26

a) Nominal scale categorizes data, ordinal scale ranks data, interval scale has equal intervals with no true zero, and ratio scale has equal intervals with a true zero.

Question 27

What is the purpose of a pilot test in Lean Six Sigma?
a) To visualize and understand the steps and flow of a process.
b) To identify the root causes of a problem.
c) To implement and test process improvements on a small scale before full implementation.
d) To track the performance of a process over time.

Answer 27

c) To implement and test process improvements on a small scale before full implementation.

Question 28

What is the concept of standard work in Lean Six Sigma?
a) The use of statistical analysis to identify process improvement opportunities.
b) The application of control charts to monitor process performance.
c) The use of standardized procedures and methods to perform tasks consistently.
d) The use of mistake-proofing techniques to prevent errors and defects from occurring.

Answer 28

c) The use of standardized procedures and methods to perform tasks consistently.

Question 29

What is the purpose of a control plan in Lean Six Sigma?
a) To visualize and understand the steps and flow of a process.
b) To identify the root causes of a problem.
c) To monitor and control process stability and variation.
d) To document the steps and measures to maintain process performance.

Answer 29

d) To document the steps and measures to maintain process performance.

Question 30

What is the concept of Total Productive Maintenance (TPM) in Lean Six Sigma?
a) The process of optimizing the use of resources to eliminate waste.
b) The process of continuously improving equipment effectiveness and reducing downtime.
c) The process of involving employees in problem-solving and decision-making.
d) The process of analyzing data to identify patterns and relationships.

Answer 30

b) The process of continuously improving equipment effectiveness and reducing downtime.

Question 31

What is the purpose of a SIPOC diagram in Lean Six Sigma?
a) To visualize and understand the steps and flow of a process.
b) To identify the root causes of a problem.
c) To monitor and control process stability and variation.
d) To document the suppliers, inputs, process, outputs, and customers of a process.

Answer 31

d) To document the suppliers, inputs, process, outputs, and customers of a process.

Question 32

What is the concept of gemba in Lean Six Sigma?
a) The use of statistical analysis to identify process improvement opportunities.
b) The application of control charts to monitor process performance.
c) The process of going to the workplace to observe and understand the current state of the process.
d) The use of standardized procedures and methods to perform tasks consistently.

Answer 32

c) The process of going to the workplace to observe and understand the current state of the process.

Question 33

What is the purpose of a process capability analysis in Lean Six Sigma?
a) To visualize and understand the steps and flow of a process.
b) To identify the root causes of a problem.
c) To assess the ability of a process to meet customer requirements.
d) To track the performance of a process over time.

Answer 33

c) To assess the ability of a process to meet customer requirements.

Question 34

What is the purpose of a mistake-proofing (poka-yoke) device in Lean Six Sigma?
a) To increase errors or defects in processes.
b) To prevent errors or defects from occurring or reaching the customer.
c) To introduce variability in processes.
d) To ignore the impact of errors or defects on customer satisfaction.

Answer 34

b) To prevent errors or defects from occurring or reaching the customer.

Question 35

What is the concept of takt time in Lean Six Sigma?
a) The time taken to complete a process step or task.
b) The time taken to produce a product from start to finish.
c) The time taken to respond to a customer request or order.
d) The pace at which products or services need to be delivered to meet customer demand.

Answer 35

d) The pace at which products or services need to be delivered to meet customer demand.

Question 36

What is the purpose of a value stream map in Lean Six Sigma?
a) To visualize and understand the steps and flow of a process.
b) To identify the root causes of a problem.
c) To monitor and control process stability and variation.
d) To identify waste and opportunities for improvement in a process.

Answer 36

d) To identify waste and opportunities for improvement in a process.

Question 37

What is the concept of a mistake-proofing (poka-yoke) inspection in Lean Six Sigma?
a) The use of mistake-proofing techniques to prevent errors and defects from occurring.
b) The use of statistical analysis to identify process improvement opportunities.
c) The application of control charts to monitor process performance.
d) The use of standardized procedures and methods to perform tasks consistently.

Answer 37

a) The use of mistake-proofing techniques to prevent errors and defects from occurring.

Question 38

What is the purpose of a control chart in Lean Six Sigma?
a) To visualize and understand the steps and flow of a process.
b) To identify the root causes of a problem.
c) To monitor and control process stability and variation.
d) To track the performance of a process over time.

Answer 38

c) To monitor and control process stability and variation.

Question 39

What is the concept of 5S in Lean Six Sigma?
a) The process of optimizing the use of resources to eliminate waste.
b) The process of continuously improving equipment effectiveness and reducing downtime.
c) The process of involving employees in problem-solving and decision-making.
d) The process of organizing the workplace for efficiency and effectiveness.

Answer 39

d) The process of organizing the workplace for efficiency and effectiveness.

Question 40

What is the purpose of a process map in Lean Six Sigma?
a) To visualize and understand the steps and flow of a process.
b) To identify the root causes of a problem.
c) To monitor and control process stability and variation.
d) To track the performance of a process over time.

Answer 40

a) To visualize and understand the steps and flow of a process.

Question 41

What is the concept of a control chart in Lean Six Sigma?
a) The use of statistical analysis to identify process improvement opportunities.
b) The application of control charts to monitor process performance.
c) The use of standardized procedures and methods to perform tasks consistently.
d) The use of mistake-proofing techniques to prevent errors and defects from occurring.

Answer 41

b) The application of control charts to monitor process performance.

Question 42

What is the purpose of a problem statement in Lean Six Sigma?
a) To visualize and understand the steps and flow of a process.
b) To identify the root causes of a problem.
c) To define and describe the problem that needs to be addressed.
d) To track the performance of a process over time.

Answer 42

c) To define and describe the problem that needs to be addressed.

Question 43

What is the concept of cycle time in Lean Six Sigma?
a) The time taken to complete a process step or task.
b) The time taken to produce a product from start to finish.
c) The time taken to respond to a customer request or order.
d) The time taken to implement process improvements.

Answer 43

a) The time taken to complete a process step or task.

Question 44

What is the purpose of a project charter in Lean Six Sigma?
a) To visualize and understand the steps and flow of a process.
b) To identify the root causes of a problem.
c) To define the project goals, scope, and team.
d) To track the performance of a process over time.

Answer 44

c) To define the project goals, scope, and team.

Question 45

What is the concept of a control plan in Lean Six Sigma?
a) The use of statistical analysis to identify process improvement opportunities.
b) The application of control charts to monitor process performance.
c) The use of standardized procedures and methods to perform tasks consistently.
d) The use of mistake-proofing techniques to prevent errors and defects from occurring.

Answer 45

c) The use of standardized procedures and methods to perform tasks consistently.

Question 46

What is the purpose of a process capability analysis in Lean Six Sigma?
a) To visualize and understand the steps and flow of a process.
b) To identify the root causes of a problem.
c) To assess the ability of a process to meet customer requirements.
d) To track the performance of a process over time.

Answer 46

c) To assess the ability of a process to meet customer requirements.

Question 47

What is the concept of Kaizen in Lean Six Sigma?
a) The process of optimizing the use of resources to eliminate waste.
b) The process of continuously improving equipment effectiveness and reducing downtime.
c) The process of involving employees in problem-solving and decision-making.
d) The process of analyzing data to identify patterns and relationships.

Answer 47

c) The process of involving employees in problem-solving and decision-making.

Question 48

What is the purpose of a fishbone diagram (Ishikawa diagram) in Lean Six Sigma?
a) To visualize and understand the steps and flow of a process.
b) To identify the root causes of a problem.
c) To monitor and control process stability and variation.
d) To track the performance of a process over time.

Answer 48

b) To identify the root causes of a problem.

Question 49

What is the concept of value-added activities in Lean Six Sigma?
a) Activities that directly contribute to meeting customer requirements.
b) Activities that do not contribute to meeting customer requirements.
c) Activities that are necessary but do not add value to the customer.
d) Activities that are unnecessary and should be eliminated.

Answer 49

a) Activities that directly contribute to meeting customer requirements.