Deck 13: Six Sigma Management and Lean Tools

Question 1

The aspect of Six Sigma that has made it popular with CEOs is ________.

A) its similarity to continuous improvement programs
B) its repackaging of quality tools and philosophies
C) its organization into different levels
D) the contingency perspective
E) its cost-reduction orientation

Answer 1

E

Question 2

Process FMEA, process capability assessments, basic statistics, and decision making are the tools used in the ________ phase of the DMAIC process.

A) define
B) measure
C) analyze
D) improve
E) control

Answer 2

B

Question 3

In lean-Six Sigma, the Japanese term "muda" is often used to describe ________.

A) process waste
B) machine processing
C) product testing
D) decision making
E) simulation

Answer 3

A

Question 4

Two important measures that are monitored in the process map are ________.

A) payback period and ROI
B) risk and return
C) defects per unit (DPU) and defects per million opportunities (DPMO)
D) breakeven point and payback period
E) contribution margin and breakeven point

Question 5

The Sigma in Six Sigma refers to the ________.

A) mean
B) standard deviation
C) skewness
D) kurtosis
E) hypothesis

Question 6

________ get information from a variety of sources such as the voice of the business, the voice of the customer, and the voice of the employee for potential project ideas.

A) Orange belts
B) Premiers
C) Champions
D) Master black belts
E) Green belts

Question 7

The Six in Six Sigma refers to the ________.

A) number of standard deviations from a specification limit to the mean of a highly capable process
B) number of means from a specification limit to the standard deviation of a highly capable process
C) number of variances from a specification limit to the mean of a highly capable process
D) number of means from a specification limit to the variances of a highly capable process
E) number of means from zero of a highly capable process

Question 8

Six Sigma translates to a defect rate of ________.

A) 233 parts per million
B) 23 parts per million
C) 3.4 parts per million
D) 0.2 parts per million
E) 6,210 parts per million

Question 9

At the core of Six Sigma is the equation Y = f(X) where f represents ________.

A) key business objectives
B) processes
C) interrelationships to be controlled and managed
D) people
E) controllable variables

Question 10

Which key player in Six Sigma is trained in basic quality tools and works in teams to improve quality on less critical projects?

A) champion
B) master black belt
C) black belt
D) green belt
E) premier

Question 11

In the context of Six Sigma, the acronym ppm stands for ________.

A) pages per minute
B) parts per million
C) project portfolio management
D) process performance manager
E) pay per minute

Question 12

At which company did Six Sigma originate?

A) General Electric
B) Motorola
C) AT&T
D) 3M
E) CIGNA

Question 13

Some quality practitioners are uncomfortable with Six Sigma's results orientation because ________.

A) it violates several of Deming's points
B) quality is inherently unfocused
C) results are impossible to measure
D) the practice was developed in a different culture
E) the program is relatively new and does not have proven results

Question 14

DMAIC is an acronym for ________.

A) Define, Measure, Analyze, Improve, Control
B) Design, Measure, Apply, Invest, Correlate
C) Design, Model, Analyze, Invest, Control
D) Design, Model, Analyze, Improve, Correlate
E) Define, Measure, Apply, Invest, Correlate

Question 15

Business cases, process mapping, voice of the customer, change management, and problem/objective statements are the tools used in the ________ stage of the DMAIC process.

A) define
B) measure
C) analyze
D) improve
E) control

Question 16

At the core of Six Sigma is the equation Y = f(X) where Y represents ________.

A) key business objectives and measures
B) processes
C) interrelationships to be controlled and managed
D) uncontrollable variables
E) controllable variables

Question 17

The efficacy of a business case is checked using the mnemonic RUMBA. The "M" in RUMBA stands for ________.

A) methods
B) materials
C) motivation
D) measurable
E) manpower

Question 18

Which key player in Six Sigma is a specially trained individual who is a specialist?

A) champion
B) master black belt
C) black belt
D) green belt
E) process owner

Question 19

In the ________ phase, projects are identified and selected.

A) define
B) measure
C) analyze
D) improve
E) control

Question 20

Which key player in Six Sigma works with black belts to identify possible projects and is at the CEO or VP level depending on company size?

A) master black belt
B) champion
C) green belt
D) orange belt
E) premier

Question 21

What is the Taguchi constant for a device that costs $300 to repair and a tolerance of plus or minus 3 mm with a mean squared deviation from the target of 0.2?

A) 1.33
B) 7500
C) 67500
D) 300
E) 33.3

Question 22

The P-value in the ANOVA table shows what variables ________.

A) need to be standardized
B) are redundant
C) are independent and identically distributed
D) significantly contribute to the variation
E) are out of control

Question 23

The process of designing products so they are inherently defect-free and insensitive to random variation is known as ________.

A) robust design
B) concept design
C) parameter design
D) tolerance design
E) finish design

Question 24

The goal of the ________ step is to use visual and statistical tools to better understand the relationships between dependent and independent variables.

A) defining objectives
B) identifying Xs
C) analyzing sources of variation
D) gauge R&R
E) Pareto analysis

Question 25

Hypothesis tests, design of experiments, simulation, and piloting and testing are the tools used in the ________ stage of the DMAIC process.

A) define
B) measure
C) analyze
D) improve
E) control

Question 26

FMEA is used to ________.

A) check the efficacy of a business case
B) identify ways a process or product can fail to meet critical customer requirements
C) determine the accuracy and precision of your measurements
D) identify inputs (Xs) and outputs (Ys) from a project that has mapped and are desiring to pursue
E) identify non value added activities

Question 27

The ________ is used to identify inputs (Xs) and outputs (Ys) from a project that has been mapped and is desired to be pursued.

A) X,Y scatter plots
B) XY differentiation method
C) X,Y covariance analysis
D) XY matrix
E) XY nonlinearity analysis

Question 28

________ is used to determine if measurements are consistent.

A) Matrix synchronization analysis
B) Multiple systems analogues
C) Maximal system adjustment
D) Minimal system adjustment
E) Measurement system analysis

Question 29

The XY matrix identifies ________ from a project you have mapped.

A) inputs and outputs
B) customers and suppliers
C) high and low quality processes
D) waste and gain
E) expenditures and savings

Question 30

Graphical data analysis, hypothesis tests, and process modeling and simulation are the tools used in the ________ phase of the DMAIC process.

A) define
B) measure
C) analyze
D) improve
E) control

Question 31

In the Taguchi method, levels of parameters are also known as ________.

A) mixes
B) settings
C) factors
D) treatments
E) models

Question 32

The process of examining competing technologies to produce a product is known as ________.

A) robust design
B) concept design
C) parameter design
D) tolerance design
E) finish design

Question 33

What are the two major steps in the measure phase?

A) selecting process outcomes and mapping non value added activities
B) selecting process outcomes and verifying measurements
C) understanding the process and mapping non value added activities
D) understanding the process and verifying measurements
E) mapping non value added activities and verifying measurements

Question 34

What is the Taguchi constant for a device that costs $400 to repair and a tolerance of plus or minus 0.5 mm with a mean squared deviation from the target of 0.3?

A) 144
B) 450
C) 4400
D) 1600
E) 1100

Question 35

The process of developing specification limits is known as ________.

A) robust design
B) concept design
C) parameter design
D) tolerance design
E) finish design

Question 36

Offline experimentation is performed during the ________ phase.

A) control
B) improve
C) analysis
D) identification
E) variation

Question 37

Which step in the analyze phase of DMAIC involves determining what characteristics of the process need to be changed to achieve improvement?

A) analyze sources of variability
B) improvement projection
C) independent variable identification
D) performance objectives definition
E) return to control

Question 38

Solution selection, solution implementation, control charts, and best practices are the tools used in the ________ stage of the DMAIC process.

A) define
B) measure
C) analyze
D) improve
E) control

Question 39

The Taguchi method focuses primarily on ________.

A) robust design
B) concept design
C) parameter design
D) tolerance design
E) finish design

Question 40

The process of selecting control factors and determining optimal levels for them is known as ________.

A) robust design
B) concept design
C) parameter design
D) tolerance design
E) finish design

Question 41

What is the Taguchi constant for a device that costs $200 to repair and a tolerance of plus or minus 0.25 mm with a mean squared deviation from the target of 0.6?

A) 1152
B) 556
C) 3200
D) 34.7
E) 55.6

Question 42

The Pitman arm on a car costs $105 to repair. Compute the quality loss function for losses incurred as a result of deviation from a target where a tolerance of 10 plus or minus 0.8 is required and the root mean squared deviation (V) from the target is 0.25.

A) 16.40
B) 168.0
C) 10.25
D) 107.5
E) 26.25

Question 43

The Pitman arm on a car costs $105 to repair. Compute the quality loss function for losses incurred as a result of deviation from a target where a tolerance of 10 plus or minus 0.125 is required and the root mean squared deviation (V) from the target is 0.33.

A) 672
B) 964
C) 158
D) 226
E) 732

Question 44

The Taguchi constant for flooring materials is known to be $13.33/cm sq. and the tolerance is 15 plus or minus 0.4. What is the cost to repair the flooring?

A) $2.13
B) $0.12
C) $3.94
D) $71
E) $13.47

Question 45

The loss caused by deviation from the target standard is $15.47 per unit and the Taguchi constant for the material is 247. What is the root mean squared deviation (V) from the desired target value?

A) 4.00
B) 7.50
C) 0.13
D) 3.67
E) 0.25

Question 46

The Taguchi constant for flooring materials is known to be $30/cm sq. and the cost to repair them is $325. What is the tolerance interval?

A) 0.3 cm
B) 3.3 cm
C) 0.09 cm
D) 10.8 cm
E) 1.11 cm

Question 47

The Pitman arm on a car costs $105 to repair. Compute the quality loss function for losses incurred as a result of deviation from a target where a tolerance of 10 plus or minus 0.75 is required and the root mean squared deviation (V) from the target is 0.025.

A) 0.18
B) 5.83
C) 16.8
D) 0.12
E) 45.0

Question 48

The Taguchi constant for flooring materials is known to be $50/cm sq. and the tolerance is 25 plus or minus 0.6. What is the cost to repair the flooring?

A) $1500
B) $83
C) $18
D) $125
E) $166

Question 49

The Taguchi constant for flooring materials is known to be $50/cm sq. and the cost to repair them is $300. What is the tolerance interval?

A) 2.45 cm
B) 0.41 cm
C) 6.00 cm
D) 0.16 cm
E) 4.25 cm

Question 50

The Pitman arm on a car costs $105 to repair. Compute the quality loss function for losses incurred as a result of deviation from a target where a tolerance of 10 plus or minus 0.2 is required and the root mean squared deviation (V) from the target is 0.05.

A) 262.5
B) 6.6
C) 420.0
D) 168.5
E) 105.0

Question 51

The loss caused by deviation from the target standard is $23.75 per unit and the Taguchi constant for the material is 95. What is the root mean squared deviation (V) from the desired target value?

A) 0.50
B) 3.00
C) 0.10
D) 2.00
E) 1.50

Question 52

What is the Taguchi constant for a device that costs $250 to repair and a tolerance of plus or minus 2 mm with a mean squared deviation from the target of 0.2?

A) 2.5
B) 62.5
C) 2625
D) 2500
E) 6250

Question 53

Variables that are under the control of management are called ________.

A) signal factors
B) noise factors
C) control factors
D) level factors
E) parameter factors

Question 54

Variables that are uncontrollable are called ________.

A) signal factors
B) noise factors
C) control factors
D) level factors
E) parameter factors

Question 55

The loss caused by deviation from the target standard is $47.70 per unit and the root mean squared deviation (V) from the target value is 0.50. What is the Taguchi constant?

A) 249
B) 191
C) 642
D) 318
E) 452

Question 56

What is the Taguchi constant for a device that costs $500 to repair and a tolerance of plus or minus 2 mm with a mean squared deviation from the target of 3?

A) 125
B) 1125
C) 55
D) 222
E) 532

Question 57

The first step in the Taguchi process is ________.

A) problem identification
B) brainstorming session
C) experimental design
D) run experiment
E) analyze results

Question 58

The Pitman arm on a car costs $105 to repair. Compute the quality loss function for losses incurred as a result of deviation from a target where a tolerance of 10 mm plus or minus 0.15 mm is required and the root mean squared deviation from the target is 0.16.

A) 119
B) 4666
C) 4101
D) 92
E) 29

Question 59

Tools to maintain independence between successive trials of a Taguchi experiment are called ________.

A) replications
B) control factors
C) parameter factors
D) signal factors
E) orthogonal arrays

Question 60

The loss caused by deviation from the target standard is $13.75 per unit and the root mean squared deviation (V) from the target value is 0.30. What is the Taguchi constant?

A) 204
B) 75
C) 153
D) 115
E) 172

Question 61

Six Sigma is popular with CEO's because it is more cost-reduction-oriented than traditional continuous improvement.

Question 62

Black belts are trained in basic quality tools and work in teams to improve quality.

Question 63

The define, measure, analyze, design, and verify methodology pertains to ________.

A) developing new processes and products
B) improving existing products and processes
C) final engineering design optimization
D) preliminary engineering design
E) customer quality metrics

Question 64

In the Six Sigma equation, Y = f(X), the variable X represents output or key business objectives.

Question 65

The basic seven (B7) tools of quality can be used to handle 90% of the quality problems that a firm typically encounters.

Question 66

DMAIC is very similar to Deming's PDCA cycle.

Question 67

Gage R&R is used to determine the consistency and thickness of materials.

Question 68

The analyze phase of a Six Sigma project is used to select an appropriate project for improvement.

Question 69

A measurement systems analysis (MSA) is used to determine if measurements are consistent.

Question 70

________ is focused on final engineering design optimization.

A) DFSS
B) DMAIC
C) IDOV
D) DFMS
E) DDSS

Question 71

The measure phase involves two major steps, selecting process outcomes and verifying measurements.

Question 72

The goal with a process map is to identify the sequence of steps in a process.

Question 73

Part of the responsibility of the master black belt is to perform a cost of poor quality analysis.

Question 74

In the Six Sigma equation, Y = f(X), the variable Y represents interrelationships to be managed.

Question 75

The XY matrix is used to identify inputs and outputs from a project that has been mapped.

Question 76

The job of the master black belt is to work with black belts to identify possible projects.

Question 77

The sigma in Six Sigma refers to the Greek symbol that designates a mean in statistics.

Question 78

Six Sigma is a program begun at General Electric in 1982 by Jack Welch.

Question 79

A process that meets the statistical notion of Six Sigma produces 3.4 defects per million pieces produced.

Question 80

When defining objectives in the analyze phase, you are attempting to determine what characteristics of the process need to be changed to achieve improvement.