IASSC Certified Lean Six Sigma Yellow Belt

IASSC Certified Lean Six Sigma Yellow Belt (ICYB) Practice Exam Questions With 100% Correct Answers Which is a purpose and use of data visualization? Correct Answer: Allows conclusions to be drawn from graphical data analysis Which of the following are examples of continuous data? Number of features Size in centimeters Weight in kilograms Pressure per square centimeter Correct Answer: 2, 3, 4 What is 'Little's' formula for calculating Average Lead Time? Correct Answer: Number of units required, divided by production capacity All of the following are benefits of control plans except? Correct Answer: Helps to analyze and eliminate potential x's Which of the following would likely be a CTQ (Critical-to-Quality) for the purchase of a service? Required no redo All of these answers are correct Was timely in delivery Documentation is clear Correct Answer: All of these answers are correct One of the primary benefits of your team working together to create an X-Y Diagram is that the data collected from this exercise is accurate and certain. t/f - Correct Answer: False The RPN or Risk Priority Number is used to rank the various Failure Modes as to their impact on the output of the subject process. t/f - Correct Answer: True 5S Sorting: Items used weekly should be kept _______? Correct Answer: In a local location As we begin to describe the things occurring with our process through a Process Map we begin to see some steps that are NVA which stands for ___________. Correct Answer: Non-value add Why is the 'One-Factor-at-a-Time' (OFAT) approach inferior to the 'Design of Experiments' (DOE) approach? Correct Answer: Interactions between factors are NOT revealed As we attempt to find a commonality of terms to assess the performance of a broad range of processes we use a key metric called the DPMO which stands for __________________________? Correct Answer: Defects per million opportunities A Belt has determined that the insurance claim form needn't be reviewed by accounting thereby improving the number of claims a processer can handle. According to Cost of Poor Quality (COPQ) definitions RTY improvement would be considered _______________. Correct Answer: Hard savings When we create a Process Map and want to depict an action step in the process we would use the ____________ symbol. Correct Answer: Rectangle Systems and structures are the basis for allowing people to change their behaviors permanently and are accomplished through which of the following? A. Documented performance objectives B. Defined procedures C. Accurate job descriptions D. Incentive compensation Correct Answer: E. All of these answers are correct When we create a Process Map we use a __________ to show the direction of work flow. Correct Answer: Solid line arrow Benefits and working conditions would be primarily the concern of which of the following? Correct Answer: Voice of the Employee The following Business Case is constructed properly. "During most of 2008 Division 16 experienced a 4.2% product return rate versus a target of nearly no returns. This costs the company a whole bunch of money." T/F - Correct Answer: False The Value Chain in an organization is the sum total of all the processes which occur in the business to take inputs and turn them into customer desired outputs. T/F - Correct Answer: True When a process has proven itself to function at a Six Sigma level this means there are less than 3.4 defects per ___________ opportunities. Correct Answer: Million The ROI for a project is a measurement metric that stands for Return on Investment and is one of the methods used to measure the success of a Lean Six Sigma project. T/F - Correct Answer: True Voice of the Customer is a Lean Six Sigma technique to determine the ___________ attributes of a product or service. Correct Answer: Critical-to-Quality At the start of a project we are told to "walk the process" from beginning to the end. We do this to_____________________. Correct Answer: Draft a Process Map To construct a Fishbone Diagram and capture all the issues of interest it is best if your team uses the ________________ approach. Correct Answer: Brainstorming When we assess the Voice of the Customer we are attempting to determine the gaps in our processes between "what is" and __________________. Correct Answer: "What should be" A tool we use to identify possible failures (defects) in our process and the impact they may have is the _________________. Correct Answer: FMEA The Control Plan is created following the finalization of the Measure Phase and can be closed when? Correct Answer: Never, a Control Plan must stay in place Measurement System Analysis is a procedure used to quantify variation of the method or system used for taking measurements and used to assure usable data is collected. T/F - Correct Answer: True A 5 Why Analysis is used to help identify possible defect causes when which one of the below listed tools is created? Correct Answer: Fishbone Diagram Six Sigma refers to a process whose output has at least 95% of its data points within 6 Standard Deviations from the Mean. Correct Answer: False When a Belt wishes to clarify the activities of various departments in a Process Map she is creating she adds a feature to the map called _______________. Correct Answer: Swim Lanes If a set of data is generally centered relative to the targeted value but is rather widely disbursed it would be said to be _____________. Correct Answer: Accurate but not precise As we identify customer and supplier requirements for a SIPOC we are urged to use the RUMBA approach which stands for Reasonable, Understandable, _____________, Believable and Achievable. Correct Answer: Measurable Cycle Time, Defects, Scrap Cost and Safety are examples of business metrics or commonly referred to as which of the following? Correct Answer: Key Performance Indicators One of the primary objectives of constructing an X-Y Diagram is to separate the vital few Y's from the trivial many Y's. T/F - Correct Answer: False The Pareto Chart is a tool that displays data that typically follows what ratio? Correct Answer: 80:20 A Monitoring Plan put into place at the conclusion of a project will provide for adequate systems with key metric readouts indicating out-of-spec conditions. T/F - Correct Answer: True In the expression Y = f(Xn) Y, the output, is the ___________ variable and Xn, the inputs, are the __________ variables. Correct Answer: Dependent, independent Long-term Data represents all the variation that one can expect to experience from the output of the subject process. T/F - Correct Answer: True A Lean Principle that states the process of eliminating waste is a continual process requiring one to always be on the lookout for ways to reduce the seven elements of waste is known as ____________. Correct Answer: Kaizen The following Business Case is constructed properly. "During 2009 the commercial loan division experienced a 2.7% default rate versus a target of less than .5%. This costs the bank in excess of $250,000 quarterly." T/F - Correct Answer: True One of the primary benefits of your team working together to create an X-Y Diagram is that the data collected from this exercise is accurate and certain. T/F - Correct Answer: False One of the 5S approaches to eliminating waste is to organize all tools, information and inventory utilized at a workstation in such a manner that the operator knows exactly where things are when needed. This 5S tool is called __________________. Correct Answer: Straightening To reduce the people or operator introduced defects into a process it is best if a Belt can design and implement a means of ________________ into the process. Correct Answer: Full Automation The purpose of ________________ is to analyze data and present it in a way we can make informed decisions as to what is happening in our process. Correct Answer: Basic Statistics The purpose of a Process Map is to identify the complexity of the process and to assist in identifying ______________ in the process. Correct Answer: Critical steps At the beginning of a project we must keep in mind there are basically three views of a process: What you THINK it is, What the SUPPLIER wants and What it SHOULD be. T/F - Correct Answer: False Training cost $2,500 and a project required an initial investment of $23,500. If the project yields monthly savings of $2,500 beginning after 4 months, what is the payback period in months (before money costs and taxes)? Correct Answer: 14.4 As part of a Visual Factory plan _____________ are created and utilized to identify areas in need of cleaning and organization. Correct Answer: Kanban cards Process Capability is defined based on customer requirements, defect free performance and output over time. T/F - Correct Answer: T (True) As we conceive and define a LSS project one of the overriding things we hope to accomplish is to reduce the _____________________. Correct Answer: Cost of Poor Quality Systems and structures are the basis for allowing people to change their behaviors permanently and are accomplished through which of the following? A. Documented performance objectives B. Defined procedures C. Accurate job descriptions D. Incentive compensation E. All of these answers are correct Correct Answer: E. All of these answers are correct A ______________ is a graphical presentation of sample data that shows the number of times that a data point is a specific number. Correct Answer: Histogram Which of the following is a method of expressing the concept that the outputs of a process are a function of all the inputs to the process? Correct Answer: Y = f(Xn) Training cost is $3,000 and a project required an initial investment of $12,000. If the project yields monthly savings of $1,800 beginning after 3 months, what is the payback period in months (before money costs and taxes)? Correct Answer: 11.33 Six Sigma refers to a process whose output has 100% of its data points within 8 Standard Deviations from the Mean. T/F - Correct Answer: T/F Stability, Bias and Linearity define the ___________ of a Measurement System. Correct Answer: Accuracy To minimize waste through the application of Lean Principles we do which of the following? Correct Answer: Keep the work area clean and organized The "Equipment" category of Root Causes on a Fishbone Diagram would be used primarily to generate ideas as to which of the following are possible causes for defects? A. Out of calibration measurement system B. Tolerance changes in milling machines C. Worn bearings on a shaft D. All of these answers are correct Correct Answer: All of these answers are correct The "Method" category of Root Causes on a Fishbone Diagram is primarily used to generate ideas as to the possible causes for defects by the ____________. Correct Answer: Way work is done One of the 5S approaches to eliminating waste is to minimize work activities that are out of the ordinary thereby requiring unusual decisions and actions to accomplish the correct things. This 5S tool is called - Correct Answer: Standardizing One of the primary objectives of constructing an X-Y Diagram is to separate the vital few X's from the trivial many X's. T/F - Correct Answer: True Voice of the Business is a Lean Six Sigma technique to determine the needs and wants of the ______________ of the business. Correct Answer: Owners Al bought a digital camera from his local electronics store. When he first used it he found the zoom lens function was inoperative because a gear was installed improperly. For the manufacturer of the camera this would be categorized as what type of cost? Correct Answer: Internal Failure Cost A Belt gathered the following defect data for a trouser production line and wanted to assemble it into a Pareto Chart. The correct order from left to right in the chart would be: Data: Cutting: 29 Forming: 43 Stitching: 17 Sealing: 51 Correct Answer: Sealing, Forming, Cutting, Stitching An important factor in a viable Control Plan is to determine who, when and to what level various personnel must be _________ to maintain the improvements made to a process. Correct Answer: Trained A Belt gathered the following defect data for a polyurethane production line and wanted to assemble it into a Pareto Chart. The correct order from left to right in the chart would be: Data: Trimming: 37 Forming: 61 Packaging: 29 Sealing: 5 Correct Answer: Forming, Sealing, Trimming, Packaging An important factor in a viable _________ is to determine who, when and to what level various personnel must be trained to maintain the improvements made to a process. Correct Answer: Standard Operating Procedure When a process has proven itself to function at a Six Sigma level this means there are less than ________ defects per million opportunities. Correct Answer: 3.4 At the beginning of a project we must keep in mind there are basically three views of a process: What you THINK it is, What it ACTUALLY is and What is DOCUMENTED. Correct Answer: False _____________ represents all the variation that one can expect to experience from the output of the subject process. Correct Answer: Long-term Data Which of the following would likely not be a CTQ (Critical-to-Quality) for the purchase of a product? A. Functionality B. Durability C. Dependability D. None Correct Answer: None Upon completion of a project a Belt must complete the Documentation Plan then transfer responsibility for this to the ____________________. Correct Answer: Process Owner Al bought a handheld GPS from his local electronics store. When he entered an address it would not function. For the manufacturer of the GPS this would be categorized as what type of cost? Correct Answer: External Failure Cost One of the most popular measures of variability in a data set or population is _____. Correct Answer: Standard Deviation Which of the below statistical tests helps in decision making based on data inferences? Correct Answer: Hypothesis Test If you are a Team Lead encountering a positively skewed normal distribution curve for Defect Leakage Rate, then what will you conclude from the following? Correct Answer: Process needs Corrective action over Defects Q:4- In which condition of the following, a data set is a said to be a normal distribution? Correct Answer: If P value >= 0.05 Q:5- You are a Project Manager wanting to compare on time delivery (%) of Team Leads across 4 teams, your choice of technique would be? Correct Answer: Box Plots Q:6- Post delivery defects are aimed to be < 4. What will be your action, if your Project delivers 10 defects on an average? Correct Answer: Shift your mean performance within specification limits Q:7- An observation above upper Control limit is concluded as? Correct Answer: Process special cause variation Q:8- In your project, Review effort (hrs, X) and defect rate (no. of defects per hour, Y) show a negative correlation. It means : Correct Answer: As Defect Rate increases, Review Effort Hrs decreases Q:9- What is the outcome of Hypothesis Testing, where P Value >= 0.05 Correct Answer: Accept Null Hypothesis Q:10- If the effort variance of your project shows a negatively skewed normal distribution curve, what will you infer from the following? Correct Answer: This means that the project is proactively finishing ahead of time • Pre-Industrial Revolution Correct Answer: Skilled craftsmen controlled their own quality through pride of workmanship. They were involved in the product from beginning to end. • 1880'S - ______________ and "Scientific Management" Correct Answer: Frederick Taylor Mass production, assembly lines, and division of labor. Introduction of work standards and wage incentives. • 1920'S - ___________ Introduces Statistical Process Control Correct Answer: Shewhart Methods based on continual on-line monitoring of process variation. Concept of "common cause" and "assignable cause" variability. • 1930 - _____ and _________ Introduce Acceptance Sampling Methods Correct Answer: Dodge and Romig Probabilistic approach to predicting lot acceptability based on sampling results. Centered on defect detection; concept of acceptable quality level (AQL). • 1950 - ______ Introduces Statistical Process Control to Japan Correct Answer: Deming • 1970's - __________ Companies Begin Losing Market Share to Global Competitors Correct Answer: Many U.S. • 1980 - "Quality Revolution" Begins in America Correct Answer: NBC airs a white paper entitled "If Japan Can, Why Can't We?" Deming hired by Ford as a consultant. • 1984 - U.S. Government Designates ____________ as National Quality Month Correct Answer: October • 1987 - _____________ ___________ National Quality Award is Established Correct Answer: Malcolm Baldrige • 1990's - Quality Programs Spread to Service Industries Correct Answer: Proliferation of Quality programs: TQM, QFD, Six Sigma, Kaizen, Poke Yoke, Taguchi Methods, Benchmarking, CQI, FMEA, etc. PHILLIP CROSBY • FOUR ABSOLUTES OF QUALITY MANAGEMENT Correct Answer: Definition of Quality: "Conformance to Requirements" System: Prevention Performance Standard: Zero Defects Measurement: Cost of Quality CROSBY'S 14 STEPS Correct Answer: Management Commitment Quality Improvement Team Quality Measurement Cost of Quality Evaluation Quality Awareness Corrective Action Zero Defects Planning Quality Education Zero Defects Day Goal Setting Error Cause Removal Recognition Quality Councils Do It All Over Again • Four-time winner of the "Deming Award" • Joined ECL in 1949 with the charge to improve efficiency of R & D activities. Cultivated the application of designed experiments. - Advocates a three-stage process design model: System Design Parameter Design Tolerance Design • Quality Loss Function • Signal-to-Noise Ratio Correct Answer: Genichi Taguchi Definition of Quality: "Fitness for Use" Correct Answer: Joseph Juran Deming's 14 Points Correct Answer: Create Constancy of Purpose for Improvement of Product and Service Adopt the New Philosophy Cease Dependence on Mass Inspection for Quality Control End the Practice of Awarding Business on Price Tag Alone Constantly and Forever Improve the System of Production and Service Institute More Thorough, Better Job-Related Training Institute Leadership Drive Out Fear Break Down Barriers Between Departments Eliminate Slogans, Exhortations, and Targets of the Work Force Eliminate Work Standards on the Factory Floor Remove Barriers that Rob People of Pride of Workmanship Institute a Vigorous Program of Education and Self-Improvement Put Everybody in the Organization to Work to Accomplish the Transformation Six Sigma (6σ) is a set of techniques and tools for process improvement. It was introduced by American engineer _______ while working at ________ in 1986. Correct Answer: Bill Smith, Motorola _________ made it central to his business strategy at ____________ in 1995. Correct Answer: Jack Welch, General Electric A six sigma process is one in which _________ of all opportunities to produce some feature of a part are statistically expected to be ____________ of defects. Correct Answer: 99.99966%, free Features that set Six Sigma apart from previous quality improvement initiatives include: Correct Answer: A clear focus on achieving measurable and quantifiable financial returns from any Six Sigma project. An increased emphasis on strong and passionate management leadership and support. A clear commitment to making decisions on the basis of verifiable data and statistical methods, rather than assumptions and guesswork. The term "six sigma" comes from statistics and is used in statistical quality control, which evaluates _______ ___________ Correct Answer: process capability The 3.4 dpmo is based on a "shift" of ____ ____ _________ Correct Answer: ± 1.5 sigma Both systems are driven by data, though Six Sigma is much more dependent on __________ data. Correct Answer: accurate Measure key aspects of the current process and collect relevant data; calculate the 'as-is' ___________ __________. Correct Answer: Process Capability Improve or optimize the current process based upon data analysis using techniques such as ____________ __________, poka yoke or mistake proofing, and standard work to create a new, future state process. Set up pilot runs to establish process capability. Correct Answer: design of experiments Control the future state process to ensure that any deviations from the target are corrected before they result in defects. Implement control systems such as statistical process control, production boards, visual workplaces, and continuously monitor the process. This process is repeated until the desired quality level is obtained. Correct Answer: Executive Leadership - responsible for setting up a vision for Six Sigma implementation Champions Correct Answer: take responsibility for Six Sigma implementation across the organization in an integrated manner. act as mentors to Black Belts. Master Black Belts Correct Answer: identified by Champions, act as in-house coaches on Six Sigma. They assist Champions and guide Black Belts and Green Belts. Apart from statistical tasks, they spend their time on ensuring consistent application of Six Sigma across various functions and departments. Black Belts Correct Answer: they primarily focus on Six Sigma project execution and special leadership with special tasks when under the effect of the 1.5 sigma shift, is commonly referred to as a ________ sigma process Correct Answer: 4.5 6 4.5 3.4 0.00034% 99.99966% 2.00 1.5 Geoff Tennant Correct Answer: book Six Sigma: SPC and TQM in Manufacturing and Services Founders of Six Sigma Correct Answer: book Six Sigma: SPC and TQM in Manufacturing and Services foundational Lean principles created by Correct Answer: W. Edwards Deming, Joseph Juran, Philip Crosby, Kaoru Ishikawa, and Genichi Taguchi. In the 1980s, Motorola began focusing on product quality and implemented a four-point plan: Correct Answer: Global Competitiveness Participative management Quality improvements Motorola Management Institute Toyota Way Correct Answer: Jeffrey Liker The Six Sigma Way: How to Maximize the Impact of Your Change and Improvement Efforts Correct Answer: By Peter S. Pande, Robert P. Neuman, and Roland Cavanagh The Six Sigma Way Team Fieldbook: An Implementation Guide for Process Improvement Teams Correct Answer: By Peter S. Pande Juran's Quality Essentials: For Leaders Correct Answer: By Joseph A. DeFeo and Joseph M. Juran The Machine that Changed the World Correct Answer: By James P. Womack and Daniel T. Jones Kaizen Express: Fundamentals for Your Lean Journey Correct Answer: By Toshiko Narusawa and John Shook The Toyota Production System: Beyond Large-Scale Production Correct Answer: By Taiichi Ohno Gemba Kaizen Correct Answer: By Masaaki Imai Lean Thinking: Banish Waste and Create Wealth in Your Corporation Correct Answer: By Daniel Jones & James Womack Learning to See: Value Stream Mapping to Add Value and Eliminate Muda Correct Answer: By Mike Rother and John Shook The Goal: A Process of Ongoing Improvement Correct Answer: By Eliyahu M. Goldratt and Jeff Cox 2 Second Lean Correct Answer: By Paul A. Akers Pull Flow Takt time Heijunka Cell Design Smed - Correct Answer: JIT (just in time) Poka-yoke Andon Autonomation 5 ways Line stops Built in Quality - Correct Answer: JIDOKA As a Belt completes a LSS project she creates for the Process Owner a Control Plan. The ________________ portion of the Control Plan details the actions to be taken when the KPI's indicate they may be moving outside acceptable limits. A) Visual Factory B) Response Plan C) Readjustment Plan D) Variance Tracking Correct Answer: B. Response Plan When calculating the Cp index, what does the standard deviation represent in the formula Cp = (USL - LSL) / 6σ? (A) The tolerance interval (B) The confidence interval for the result (C) The range of the process (D) The variance of the index Correct Answer: C. The range of the process Cp considers the within-subgroup standard deviation and Pp considers the total standard deviation from the sample data. T/F - Correct Answer: True Which describes a 'systematic' approach to collecting a representative sample of population data? Correct Answer: Arrange objects in a list and then select every fifth entry after a random start What type of data is sometimes called variable data? Correct Answer: Continuous Specifically in Six Sigma, intentional changes in process performance comes from changing and controlling: Correct Answer: Random variables Sort these 5S's to the proper order of execution Correct Answer: Standardize Which of the following statements are about the use of 'Pull' production? Items are made to order Items are ready earlier than required Raw materials are ordered as needed Customer demand drives production Correct Answer: 1, 3, 4 A part of the Aligning Systems and Structures portion of the Control Plan establishes the proper measurement system for the process and eliminates duplicate measurements. T/F - Correct Answer: T (True) Six sigma problem-solving model based on? Correct Answer: Scientific Methods Why is the Value Stream Mapping (Current State) technique used? Correct Answer: Identifying causes of waste and opportunities for improvement What term is given to the discrete probability distribution of the number of successes in a sequence of Yes/No experiment? Correct Answer: Binomial distribution Quality control issued a 'non-conformance' due to an incorrect bolt pattern (34 holes drilled instead of 36). The causes were a combination of engineering oversight and a lack of quality checking by the machinist. What should be documented in the problem statement when attempting to resolve this issue? Correct Answer: A procedure to ensure that 36 holes are drilled every time according to the design Long-term Data represents all the variation that one can expect to experience from the output of the subject process. t/f - Correct Answer: t (True) A Kaizen Blitz is being carried out in a small retail outlet. What is the first action that should be taken by the facilitator? Correct Answer: Ask the retail staff for their ideas Which attribute is required of all Lean Six Sigma team members? Correct Answer: Active listening skills What is the difference between job aid and Standard operating procedure? Correct Answer: An SOP is longer than a Job aid Which is NOT one of the eight pillars within the TPM 'House of Quality'? Correct Answer: Emergency planning Select all that are components of a control plan? Correct Answer: Measurements Mitigation Actions Key Metrics Process that is in statistical control exhibits what type of variation? Correct Answer: Random "The constant no of parts assembled in engine" this is an example of (Poka-yoke)... Correct Answer: Fixed value method (Poka-yoke) Why is the 'One-Factor-at-a-Time' (OFAT) approach inferior to the 'Design of Experiments' (DOE) approach? Correct Answer: Interactions between factors are NOT revealed Select all reasons why one financial benefit estimation might differ from another? Correct Answer: Use of different discount rates Different assumptions on project duration Different assumption on project costs The Cpk for a process with an average of 100 and a standard deviation (within) of 2 with upper and lower specification limits of 114 and 94 would be? Correct Answer: 1 To achieve Six Sigma the DMAIC methodology follows which approach? Correct Answer: Use the transfer function Y=f(x) The measure which helps to understand the spread of variation is called as _____. Correct Answer: Variance What is the outcome when designing the optimal Value Stream? Correct Answer: Future State Value Stream Map "Missing component detection that stops the process when triggered" this is an example of... Correct Answer: Process interruption Which is the correct Defects per Million Opportunities (DPMO) calculation? Correct Answer: (D/U*O)*1,000,000 Where D=Defects, U=Units, O=Opportunities What action represents a Type I Error in a hypothesis test? Correct Answer: Rejecting the null hypothesis when it is actually true A Control Plan is finalized at the end of a Lean Six Sigma project and given to the Process Owner so she/he can follow it exactly for the remaining life of the process. Correct Answer: False What is the Cycle Time, in seconds, for a process having a Throughput of 7,200 units per hour? Correct Answer: 0.5 Which customer group is MOST likely to voice requirements about operating hours, health and safety and working conditions? Correct Answer: Operational staff If the current operational availability of an automated assembly machine is not enough to meet an increase in customer demand, what is the BEST way to improve the machine's availability? Correct Answer: Reduce breakdowns and delays What type of muda is waste from working more than required, scheduling more capacity than necessary or using resources that are overkill? Correct Answer: Over-Processing How might you display central location on a nominal scale? Correct Answer: Mode