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Six Sigma GB - Random Questions
Test Questions
179
Business
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09/25/2012
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Term
What is Yield?
 Definition
Percentage of Defects (Errors) Per Unit
Term
What is Standard Deviation?
 Definition
The Average Distance that the Value is Different From the Arithmetic Average
Term
What Steps are in the Analyze Phase?
 Definition
Develop Root Cause Hypothesis, Use Data to Test Hypothesis, Confirm or Refute Hypothesis
Term
What is Discrete Data?
 Definition
Data that can be Categorized into a Limited Classification
Term
What are Methods to Improve Data Consistency?
 Definition
Test Data Collection in Advance, Train Data Collectors, Keep an Eye on Data for Problem Signs, Continue Measuring Worthwhile Data
Term
What is Stratification?
 Definition
Breaks Down the Process in Layers;
Term
What is Value Add (Va)?
 Definition
Customer Will Pay For; Done Right the First Time:
Term
Pareto Chart
 Definition
Has Two Axis ( X-Axis it the Count / Y-Axis are the Categories; Most to Least;
Term
What are Some Values of a Pareto Chart?
 Definition
Determines If Errors (Defects) should in Most to Least Order By Type of Error or Cost of Error; Sometimes the Smaller Error Category Could Cost More; Ability to Drilldown the Most Percentage to a Second Level Pareto Chart;
Term
What is a Run Chart?
 Definition
Reviews Data Over a Period of Time, Able to Decipher Common and Special Causes
Term
What is a "Trend" in a Run Chart?
 Definition
Seven (7) Points Increasing or Decreasing in a Row
Term
What is a "Shift" in a Run Chart?
 Definition
Eight (8) Points on One (1) Side of Medial
Term
What are "Alternate Points" in a Run Chart?
 Definition
Fourteen (14) Points Changing Direction At Every Interval
Term
A Flow Chart Documents the __________?
 Definition
Process
Term
A Run Chart Documents the ________?
 Definition
Time
Term
What are Drivers of Employee Performance?
 Definition
Clear Expectations, Good Feedback, Enough Resources, Incentives, Skills, Capacity and Motivation
Term
What Steps are in the Control Phase?
 Definition
Monitoring and Response Plan to Ensure Performance is Maintained, Revision Plans to Reflect Ongoing Process Changes
Term
What are the Six (6) Parts of a Project Charter?
 Definition
Business Case, Problem Statement, Goal Statement, Scope, Team Members and Resource Allocation and Preliminary Plan
Term
What Steps are in the Define Phase?
 Definition
Project Charter, VOC, Walk and Map the Current Process, Stakeholder Analysis
Term
What should you Watch Out for in a Problem Statement?
 Definition
Stated Cause, Stated Solution, Blame or Responsibility
Term
What are the Function Symbols in a Flowchart?
 Definition
Square=Task/Activities Diamond=Decisions Circle/Oval=Start/End Arrow=Next Step
Term
What is First Pass Yield (FPY)?
 Definition
The Amount of Units Moving Through the Process Being Handled Correctly the First and Only Time.
Term
Would First Pass Yield (FPY Always be the Same or Less than Final Yield?
 Definition
Yes, FPY is Often Less than the Final Yield Due to Defects Being Removed From the Process
Term
What is the Most Important Criteria for Project Selection?
 Definition
Meets Company Goals
Term
What are the Four Components of Measurement Systems Analysis?
 Definition
Accuracy, Repeatability, Reproducibility & Stability
Term
What is the Pneumonic for Goal Statements?
 Definition
Smart; Specific, Measureable, Attainable, Relevant and Time Bound
Term
What are Three Things a Good Problem Statement Has?
 Definition
Names the Process or the Unit Moving Thru the Process, Quantifies the Problem (Or Starts with a Placeholder when Data is not Available), Impact, No Causes, No Blame and No Solutions
Term
What Makes for a Good DMAIC Project?
 Definition
Problem with Cause Unknown, No Solutions Known, Relates to the Business Goals - Usually Cycle Time or Defect Reduction Types of Opportunities
Term
Would a DMAIC Project have a Goal Statement that Starts with "Redesign"?
 Definition
No, it Would Start with Reduce, Decrease or Increase
Term
What is the Calculation for Capability If All we have is the Upper Spec Limit?
 Definition
Cpu = USL - the mean (average)/ 3 Times the Std Dev
Term
Would First Pass Yield Always be the Same or Less than Final Yield?
 Definition
Yes, First Pass Yield is Often Less as Anything with a Defect Would be Considered "Removed" From the Process
Term
What is the Best Tool to Use for Root Cause Analysis?
 Definition
Fishbone; Cause & Effect; Ishikawa Diagram - Note, you Could Use Just the 5 Whys Approach
Term
Could a Team Use a Scatter Plot in Order to Test Hypotheses At the Beginning of a Project?
 Definition
Yes; Knowledge or Experience May Give you Ideas of X Variable that Result in a Change in Y (Outcomes or Outputs) and If you have Data and can Prove that Going into a Project it May Help with Scoping and Focus
Term
Should a Team Ask an Executive Sponsor to be Part of the Core Team Make-Up?
 Definition
No
Term
What Type of Sampling Strategy Would Best be Used with Process Sampling?
 Definition
Systematic; Every Nth One
Term
Are Control Limits and Spec Limits the Same?
 Definition
No, Control Limits Come From the Process, Spec Limits Come From the Customer
Term
What is the Operational Definition of a Standard Deviation?
 Definition
The Measure of Variation (Change) Away From the Average of the Process
Term
If a Process is in Control, Does that Always Mean it is Capable?
 Definition
No, Control is About the Voice of the Process; Capability is Based on Voc
Term
If a Process is in Control, Does than Mean it is Efficient?
 Definition
No, Many Process Remain Within Control Boundaries But are very Costly to Maintain
Term
Should a Team Change Control Limits Every Time they Want to Plot the Next Data Point?
 Definition
No, Only Change Control Limits After you have Made a Process Change and have 30 New Points of Data
Term
Name Three Ways to Gather VOC Data.
 Definition
Focus Groups, Surveys, Interviews, Behavior Measures, Complaints
Term
Should a Team Always Hire an Outside Firm to do Benchmarking Studies.
 Definition
No
Term
Is the Role of a Process Owner is a Part Time Role?
 Definition
No, Champion is Part Time, Process Owner is Permanent
Term
At whatPoint in the Project should a Team Identify the Process Owner?
 Definition
At the very Beginning
Term
What are Some Examples of Items that Could be on Team Ground Rules?
 Definition
Only 2 People Speak At Once, be on Time; No Judgment of People's Ideas, 3 People are Enough to Hold the Meetings; be Respectful of Others, Las Vegas Rules (Note: you May have Others - as Long as they are Behaviors for Your Team to Agree to they are Probably Ok
Term
What is the Calculation for Capability when the Team Only has the Lower Spec Limit?
 Definition
The Average of the Process - the LSL Divided By 3 Times the Standard Deviation
Term
Does Correlation Always Mean Causation?
 Definition
No
Term
If a Team is Counting Proportions of Defects, is that Continuous or Discrete Data?
 Definition
Discrete
Term
What is an Example of Continuous Data?
 Definition
Anything on a Scale or Continuum; Money, Time, Speed, Distance
Term
If a Team has Continuous Data, Name Two Different Types of Control Charts they May Use.
 Definition
X-Bar & R or I & MRCharts
Term
If I Needed to Determine the Best Control Chart to Use, whatTool Could I Reference?
 Definition
The Decision Tree in the Control Materials of the GB Training meetings
Term
If a Team Needs to Understand Which Type of Error Seems to be the Worst, whatCommon Charting Technique Could they Use?
 Definition
Pareto Chart
Term
If a Team Sees 5 Out of 8 Data Points on One Side of the Median on a Run Chart, should they Immediately Go Make Changes to the Process?
 Definition
No, that is Referred to as Tampering
Term
A Team Needs to See the Distribution of Their Process So they Can Understand the Range of Variation; Which Graph Would Work Best?
 Definition
Histogram
Term
How Many Points of Data should you have to Calculate Standard Deviation?
 Definition
30 of Continuous Data
Term
What Type of Data do you Need to Calculate Standard Deviations?
 Definition
Continuous Data
Term
Why should a Team Translate VOC Into Requirements?
 Definition
In Order to Measure the Process Against the Specs to Determine Capability
Term
What is the Most Important Thing to Consider when Collecting Data?
 Definition
To Get Truly Representative Data
Term
What is the Biggest Problem to Avoid in Sampling?
 Definition
Avoid Bias
Term
Random Sampling Usually Works Best when you have whatKind of Situation?
 Definition
Population Sampling
Term
Is Y is Independent of X?
 Definition
Y is Always Dependent on X
Term
What is the X Axis on a Run Chart?
 Definition
Increments of Time or Time Sequence Order of Samples
Term
What are the Three Signals of Special Cause in a Run Chart?
 Definition
8 Consecutive Points on One Side or the Other of the Median; 7 or More Consecutive Points in an Upward or Downward Pattern; 14 or More Consecutive Points Up and Down Crossing the Median Line
Term
The Definition of "Special Causes" of Variation Means that it is Expected, Normal and Random. (True or False)
 Definition
False; that is the Definition of Common Cause
Term
The Champions Role is to Remove Roadblocks and to Communicate Issues Between the Leadership Team and the Project Team. (True or False)
 Definition
**TRUE**
Term
A Team should Wait Until they are Ready to Implement Their Solutions Before they Begin Project Planning. (True or False)
 Definition
__FALSE__
Term
Is This a Good Example of a Problem Statement: "The Group in NY Does Things Differently than the Group in California?"
 Definition
No
Term
Increase Sales By 20x; is This a Good Goal Statement?
 Definition
No
Term
The 80/20 Rule is Based on whatCharting Technique?
 Definition
Pareto Principal; Pareto Chart
Term
How Many Points of Data should you have for a Run Chart?
 Definition
Minimum 30 Data Points
Term
What Type of Data should you Use for a Run Chart?
 Definition
Continuous or Discrete
Term
What is the X Axis of a Control Chart?
 Definition
Time or Time Sequence Order of a Sample
Term
Who are we Referring to when we Discuss Capability?
 Definition
Customer
Term
What is the Name of the Component in a Charter Where a Team Explains the Need to Work on This Issue Now Vs. Later?
 Definition
Business Case Statement
Term
What Tool Works Best to Help a Team Identify How Much Work they should Take on with a DMAIC Project?
 Definition
In and Out of Frame; Scope
Term
If you Change the Boundaries of a SIPOC, Will it Potentially Change Who the Customer or Suppliers Are?
 Definition
Yes
Term
What is the Rule of Thumb for How Many Steps should be in a SIPOC?
 Definition
4 to 7
Term
An Input is Considered an X Variable. (True or False)
 Definition
**TRUE**
Term
Total Cycle Time Would be a Good Example of Y Data. (True or False)
 Definition
**TRUE**
Term
How do you Calculate Rolled Thru-Put Yield?
 Definition
% Yield X % Yield X % Yield (Across All Process Steps)
Term
What is the Definition of a Defective Unit?
 Definition
Any Unit with 1 or More Defects
Term
DPMO Uses Defective Units in the Calculation. (True or False)
 Definition
False - it Uses Specific Defects
Term
Continuous Data is More Powerful Statistically Speaking, and Can be Used with Fewer Data Points. (True or False)
 Definition
**TRUE**
Term
You Can Change Discrete Data Into Continuous Data. (True or False)
 Definition
__FALSE__
Term
Asking "Why?" Five Times Helps to Get to Root Causes, or to Narrow Down the Ideas on a Fishbone to Get to Root Causes. (True or False)
 Definition
**TRUE**
Term
What is the Rule of Thumb for How Long a Team should Collect Data?
 Definition
At Least 4 Times the Business Cycle
Term
Should a Team Just Follow the Advice of Someone in the Organization Who Tells Them to Just Go Get 20 Points of Data and Move On?
 Definition
Never
Term
Would you Suggest to a Team that a Pilot is not Necessary?
 Definition
No
Term
Do you have to Use Every Tool Taught in GB Training in Order to be Effective with DMAIC?
 Definition
No
Term
What Would you Suggest a Team do Once they have a Pareto Done?
 Definition
If you Want to Drill Down to a Second Level you can do that, But a Pareto is a Great Lead in to a Fishbone
Term
If a Team Uses a Scatter Plot Early on in a Project, should they do One Again to Prove Root Causes?
 Definition
Yes Possibly, to Prove Hypotheses of Causes
Term
The Best Way to Know Statistical Significance with Discrete Data is to Use a Chi-Square Analysis. (True or False)
 Definition
**TRUE**
Term
The Best Tool to Understand whatCould Go Wrong (Risk) is What?
 Definition
FMEA -- Failure Modes Effects Analysis
Term
What is a Tool that a Team Could Use to Help Them Decide on the Best Solution?
 Definition
Decision Criteria Matrix
Term
What are the Rules of Brainstorming?
 Definition
No,Judgment; No Filtering, the Faster the Better, the More Creative the Better, Record Exactly whatis Said
Term
You should Always do Brainstorming Out-Loud. (True or False)
 Definition
False, you Need to Use the Best Approach to Suit the Audience
Term
What are the Components of a Control Plan?
 Definition
FMEA and Process Mgmt (Maps, Monitoring Plan and Response Plan)
Term
What are Some Things to Consider when Creating Documentation?
 Definition
Watch Out for Acronyms or Abbreviations, Jargon or Technoese; Write to an 8th Grade Level; Use Graphics as Much as Possible; How to Manage Revisions
Term
Could a Team Use a Chi-Square Analysis to Prove a Change Was Made Between the Before and After State of a Process?
 Definition
Yes
Term
A Stakeholder is Always a Customer. (True or False)
 Definition
False, a Customer is a Type of Stakeholder But not All Stakeholders are Customers
Term
When Identifying Those People in the Organization that Care About the Changes we Might Make, whatTool Can a Team Use?
 Definition
Stakeholder's Analysis Worksheet
Term
Most People Enjoy Change. (True or False)
 Definition
False, Even Good Changes can be Stressful to People
Term
The Best Time of Day for Brainstorming and Being Creative is 8am. (True or False)
 Definition
__FALSE__
Term
The Venue May have an Impact on How Create a Team Can Be. (True or False)
 Definition
**TRUE**
Term
A List of Behaviors a Team Will Agree to Abide By are Referred to as____ (What?)
 Definition
Ground Rules
Term
DPMO is a Calculation that the Customer Cares About. (True or False)
 Definition
**TRUE**
Term
Yield is a Calculation that the Customer Cares About. (True or False)
 Definition
**TRUE**
Term
What are Some Examples of Non-Value Added Work?
 Definition
Moves, Decisions, Inspections and Controls, Rework, Approvals
Term
To be Considered a Value Added Step, it Must Meet what3 Criteria?
 Definition
1) the Customer Cares About the Step, 2) Transforms the Unit Moving Thru the Process, 3) Done Right the First Time
Term
In DMAIC Thinking, a Team should First Try to Prevent a Problem From Occurring. (True or False)
 Definition
**TRUE**
Term
What is it Called when we Use Devises or Warning Signals that Prevent Us or the Customer From Having a Problem with the Process or Product?
 Definition
Poka Yoke (Mistake Proofing)
Term
If a Team Does not Consider Ways to Prevent Someone From Going Back to the Old Way During a Crisis, the Process Change May not be Effective Over Time. (True or False)
 Definition
**TRUE**
Term
Process Maps should be Used for what Purpose?
 Definition
Identify Bottlenecks, Gaps, Non-Value Added Steps, Perform Cy Analysis, Perform COPQ
Term
Ctqs Refers to the Customers Address. (True or False)
 Definition
False; CTGS are Critical to Quality or the Needs of Customers
Term
A Team should Still Consider Solutions If they do not Help to Achieve the Goal in the Charter. (True or False)
 Definition
No, not Really
Term
The Calculation of How Much a Solution Will Cost and the ROI is Called (What)?
 Definition
Cost Benefit Analysis
Term
The Calculation of whata Process Costs the Business to Run, in it's Current State is Referred to as ____ (What)?
 Definition
COPQ
Term
A Team should Always Address the Costs of the Process in the Charter. (True or False)
 Definition
Impact is Often Referred to as $; the Financial Opportunity is very Often Addressed in the Business Case or in the Problem/Goal Statements
Term
Correlation = Causation (True or False)
 Definition
__FALSE__
Term
Every Project Will Fit with DMAIC. (True or False)
 Definition
__FALSE__
Term
Project Ideas Can Come From Employees, Customers and Managers. (True or False)
 Definition
**TRUE**
Term
What are Some of the Things that Could Go Into COPQ?
 Definition
Labor Hours, Especially with Non-Value Added Steps, Service Recovery Costs, Scrap, Excess Inventory & Any Special Space or Equipment to Handle It; Additional Shipping Expenses
Term
What Steps are in the Improve Phase?
 Definition
Brainstorm, Prioritize and Select Solutions, Develop Implementation Plan, Pilot Solutions, Implement the Solutions, Validate the Impact
Term
What is the Premise of Lean?
 Definition
Eliminate Waste and Maximize Flow
Term
What is the Premise of Six Sigma?
 Definition
Minimize Variation and Defects
Term
What Does Lean and Six Sigma Offer to a Process?
 Definition
Identifies Root Causes, Increases Efficiency and Enhancing Effectiveness
Term
What is Lean Six Sigma?
 Definition
A Philosophy for Operational Excellence, a Process Improvement Methodology and a System of Management to Achieve Lasting Leadership and Top Performance.
Term
What are Some Benefits of Lean Six Sigma?
 Definition
Drives Profitability, Understand Customer Requirements, Improves Internal Efficiency and Effectiveness, Empowers Employees of All Levels, Gains a Competive Advantage and Decision Making is Based on Data.
Term
What Tools are Used in the Lean Process?
 Definition
8 Wastes, 5s, Spaghetti Chart, Gemba Walk, Value Stream Map, Visual Workplace, Batch Size Reduction, Standard Work, Pull Production, Cell Layout, One-Piece Flow
Term
What Tools are Used in the Six Sigma Process?
 Definition
Project Charter, Swim Lane Map, Mesa, Data Collection Plan, Histogram, Root Cause Analysis, Cause and Effect Diagram, Design of Experiments, Statistical Test, Spec, Control Chart
Term
What are Common Goals for the Lean Six Sigma Process?
 Definition
Customer Focused, Eliminate Non-Value Add Steps, Reduce Variation, Increase Speed, Reduce Errors, Increase Profits
Term
What are the 8 Wastes?
 Definition
Downtime -- Defects, Overproduction, Waiting, Non-Utilized Talent, Transportation (Stuff Moving), Inventory, Motion (People Moving) and Extra Processing
Term
What Findings Would Lead you to Use the Full DMAIC Process?
 Definition
Cause Unknown/Uncertain; Data is Available; Time to Conduct Analysis
Term
What is the Methodology of Six Sigma - DMAIC?
 Definition
Define/Identify the Problem, Develop a Base Line Measurement of Current State of Process, Analyze Data and Root Cause, Improve, Implement Test and Confirm Solution and Develop Control Plan to Sustain the Gain
Term
What are Some Good Team/Meeting Ground Rules?
 Definition
Be on Time, No Judgment of People's Ideas, 3 People are Enough to Hold the Meetings, be Respectful of Others, Las Vegas Rules, One Person Speaks At a Time.
Term
What are the Three Core Principles of Lean Six Sigma?
 Definition
Focus on the Customer, Using Facts and Data to Make Decisions, Involving the People that do the Work, Process Management
Term
What is the Basic Philosophy of Lean?
 Definition
Delighting Customers, Remove Non-Value Added Steps, Develop Workforce to Focus on Removing Waste, Improve Each Process, Organization Supports the Workforce that Assist the Customer.
Term
What is a Defect?
 Definition
Inaccurate and/or Incomplete Information, Products or Services; Failure to Meet the Customer's Needs
Term
What are Benefits of a Tollgate Review?
 Definition
To Sign Off and/or Touch Base with Sponsor
Term
What is Sir Frances Galton Known For?
 Definition
Standard Deviation, Scatter Plot, Correlation and Introduced Ways of Collecting Data (Surveys/Questionnaires)
Term
What is 3.4?
 Definition
DPMO
Term
What Steps are in the Measure Phase?
 Definition
Data Collection Plan, Baseline Current Performance, Graphically Display Baseline Data
Term
What Does Discrete Data Measure?
 Definition
Data that is Based on Counts and Cannot be Subcategorized (M/F, Region/Site, Yes/No)
Term
What Does Continuous Data Measure?
 Definition
Data that can have Almost Any Numeric Value (Size, Weight, Cycle Time, Temperature) and can Drill Down to Finer Increments.
Term
When Collecting Data, Which is Better, Discrete or Continuous Data?
 Definition
Continuous Data Because the Data is Richer and Tells More of the Process.
Term
What are the Different Type of Capabilities?
 Definition
Cpu, Cpl and Cpk
Term
What is 99.9997%?
 Definition
Yield
Term
Downtime
 Definition
Defects, Overproduction, Waiting, Non-Utilized Talent, Transportation (Stuff Moving), Inventory, Motion (People Moving) and Extra Processing
Term
Y
 Definition
Yield
Term
What is the Standard for How we Interact With/And Treat Customers?
 Definition
Service Requirement
Term
How Many Minutes should be Used when Planning a 60 Minute Meeting?
 Definition
60 Minutes
Term
What Important Information Can be Added to Inputs and Outputs in a SIPOC Map?
 Definition
Customer Requirements and Process Requirements
Term
What is the Least Reliable Source of VOC Data?
 Definition
The Opinions of the Project Team
Term
What is a Good Way to Collect VOC?
 Definition
A Survey can Gather Data From Thousand of Customers and Customer Groups
Term
Why is Effectiveness Important to the Customer?
 Definition
Determines the Customer's Specifications, Accuracy, Service Levels/Goals, On-Time and Defect Free Deliveries.
Term
Effectiveness is Important to the _____?
 Definition
Customer
Term
Efficiency is Important to the _________?
 Definition
Company
Term
Why is Efficiency Important to the Company?
 Definition
Determines Total Cost, Resources Used, Defect Cost, Rework and Cycle Time
Term
What is Special Cause?
 Definition
An Unexpected Deviation From the Median; Large Variation;
Term
When should a Box Plot be Used?
 Definition
When Comparing Two (2) or More Pieces of "Continuous" Data; Identify Outliers;
Term
What is Correlation?
 Definition
Data Points Move Together
Term
What is Causation?
 Definition
Data Points Moves Away and Base Data Changes
Term
What is a Scatter Plot?
 Definition
A Scatter Plot can Determine If Data is Related to Correlation or Causation
Term
What is Curvilinear?
 Definition
A Bell Shape Chart; Example: Mornings are Less Busy But Volume Grows By Mid-Morning and Decreases By Lunch Time;
Term
What are Seven (7) Basic Tools for Quality?
 Definition
Cause and Effect, Check Sheet, Control Chart, Histogram (Time), Pareto Chart (80/20), Scatter Plot, Stratification
Term
Does Correlation Always Mean Causation?
 Definition
No
Term
What is the Calculation for Capability when the Team Only has the Lower Spec Limit?
 Definition
Cpl = X-LSL/ 3s
Term
What are Major Causes of Variation?
 Definition
People, Information/Metrics, Equipment/Materials, Processes/Procedures, Environment
Term
What is Critical to Quality (CTQ)?
 Definition
Requirements that Impact Customer Satisfaction and/or the Ability to Use Products and Services
Term
How do you Link Business Variables?
 Definition
Yield = Function of Variable (Process Steps) Y = F (X1, X2, X3)
Term
What is Common Cause?
 Definition
An Expected Deviation From the Median; Slight Variation; Normal and Random
Term
Six Sigma Means?
 Definition
99.9997% Yield and 3.4 DPMO
Term
What are Disqualifiers of Selection an Improvement (DMAIC) Project?
 Definition
No Time to Analyze, Root Cause is Obvious, Solution Predetermined, Low Potential Benefits
Term
What Makes for a Good Improvement (DMAIC) Project?
 Definition
**Meets Company Goals**, Root Cause in Unknown, Benefits are Significant, Data is Available, can Observe the Problem or See Gap in Existing Process.
Term
How Many Points of Data should you Use for a Run Chart?
 Definition
A Minimum of 30 Points of Data.
Term
What Type of Data should you Use for a Run Chart?
 Definition
Continuous or Discrete Data
Term
Is Y Dependent of X?
 Definition
Yes, Y is Always Dependent on X
Term
What is the X-Axis on a Run Chart?
 Definition
Increments of Time or Time Sequence Order of Samples
Term
Who are we Referring to when we Discuss Capacity?
 Definition
The Customer
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