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LEAN Six Sigma

Description

Quiz on LEAN Six Sigma, created by Ethan Plumer on 12/07/2020.
Ethan Plumer
Quiz by Ethan Plumer, updated more than 1 year ago
Ethan Plumer
Created by Ethan Plumer over 4 years ago
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Resource summary

Question 1

Question
The Lean system that enables us to recognize the standard and any deviation from it, thus corrective actions can be taken immediately is called:
Answer
  • Hoshin Planning'
  • Kaikaku
  • Visual Management
  • TRIZ

Question 2

Question
Successful Control Plans utilize which of the following type action
Answer
  • Compensating
  • Reactive
  • Preventive

Question 3

Question
Select the proper sequence of the steps in the IMPROVE Phase
Answer
  • Pilot test, Select a solution, Implement full-scale, Generate creative solution idea
  • Implement full-scale, Pilot test, Generate creative solution idea, Select a solution
  • Generate creative solution ideas, Select a solution, Pilot test, Implement full-scale
  • Select a solution, Generate creative solution ideas, Implement full-scale, Pilot test

Question 4

Question
In the improved FMEA, select the factor that its rating can be changed only by the customer.
Answer
  • Failure
  • Severity
  • Occurence

Question 5

Question
Kanban is a Lean "Push" device that allows an efficient means to transfer parts from one department to another and automatically reorder products using minimum/maximum inventory levels.
Answer
  • True
  • False

Question 6

Question
Quality at the Source is an approach to quality that places the responsibility for preventing or detecting errors in the hands of suppliers.
Answer
  • True
  • False

Question 7

Question
Select the correct definition for External Elements of Machine Changeover.
Answer
  • Operations that must be performed while the machine/process is stopped.
  • Operations that can be performed while the machine/process is running.

Question 8

Question
The Single Minute Exchange of Die process focuses on converting INTERNAL to EXTERNAL activities and creating more machine run time.
Answer
  • True
  • False

Question 9

Question
The Lean term that refers to using ingenuity to create devices that allow us to do our job 100% error free 100% of the time is
Answer
  • Kanban
  • Mistake-Proofing (or Poka-Yoke)
  • Kaizen
  • Heijunka

Question 10

Question
Calculate the Overall Equipment Effectiveness Index of a machine which is available at 80% of the time, its performance efficiency is 90%, and produces at 100% First Pass Yield.
Answer
  • 0.90
  • 0.72
  • 0.80
  • 0.89

Question 11

Question
Select the proper term for Continuous Incremental improvement.
Answer
  • Kaikaku
  • Kaizen
  • Muri
  • Poka-Yoke

Question 12

Question
Changeover time is the time elapsed between when the first good piece of product A comes off and the first good piece of product B starts.
Answer
  • True
  • False

Question 13

Question
In a value stream that includes a Push system, resources are provided to the consumer based on
Answer
  • Forecasts or schedules
  • Controlling the flow of resources by replacing only what has been consumed
  • Customer orders

Question 14

Question
In Hoshin Planning, the term "Catchball" means communication and socializing ideas.
Answer
  • True
  • False

Question 15

Question
In a value stream that includes a Pull system, resources are provided to the Customer based on
Answer
  • Forecasts or schedules
  • Controlling the flow of resources by replacing only what has been consumed

Question 16

Question
We can decide what type of control chart to use based on: 1) The types of data we have 2) What is counted (Defects, Defectives, Individuals, Rational Subgroups). We have Variable Data and we count Individuals, what control chart can we use
Answer
  • X-bar & R chart
  • Individuals and Moving Range chart
  • X-bar and S chart

Question 17

Question
We can decide what type of control chart to use based on: 1) The types of data we have 2) What is counted (Defects, Defectives, Individuals, Rational Subgroups). If we have Attribute Data and we count Defects, what two potential control charts can we use
Answer
  • c chart or u chart
  • u chart or p chart
  • u chart or np chart
  • c chart or np chart
  • c chart or p chart

Question 18

Question
In an FMEA analysis, the severity rating is 9, the occurrence rating is 3, and the detection rating is 3. Calculate the Risk Priority Number (RPN).
Answer
  • 15
  • 81
  • 3
  • 9
  • 5
  • 27

Question 19

Question
The 5 Whys is a question-asking technique used to explore the root cause of a defect or problem.
Answer
  • True
  • False

Question 20

Question
At what single point in our Value Stream will we schedule production
Answer
  • The Pacemaker
  • At the End (as near as close to the Customer)
  • At the Beginning (as near as close to the Supplier)

Question 21

Question
The place to start introducing Continuous (or SINGLE-PIECE) Flow is usually at the beginning of the "pacemaker" Process in final assembly, from which the product can flow straight through to shipping.
Answer
  • True
  • False

Question 22

Question
When we analyze the Value Stream for improvement opportunities, one typical question is whether we will be producing directly to Shipping, or we will be producing to a finished goods Supermarket. In order to build directly to Supermarket, select the one factor that is NOT part of the considerations.
Answer
  • The product is of very high value
  • Customer demand varies widely
  • The product is small enough and cheap enough to store cost effectively
  • The range of finished part numbers requiring changeovers in the Product Family is small

Question 23

Question
When we analyze the Value Stream for improvement opportunities, one typical question is whether we will be producing directly to Shipping, or we will be producing to a finished goods Supermarket. In order to build directly to Shipping, select the one factor that is NOT part of the considerations.
Answer
  • The product has many custom features
  • The product is of very high value
  • The product is small enough and cheap enough to store cost effectively
  • The product is very bulky, or is subject to spoiling

Question 24

Question
Hoshin Planning translates the strategic vision into tangible and measurable objectives for achieving the breakthrough.
Answer
  • True
  • False

Question 25

Question
In order to improve the capability of a process, the FIRST action we must take is:
Answer
  • Start adjusting the process around
  • Put the process On Target (Center it around the Mean)
  • Reduce the Variation

Question 26

Question
Cause and Effects (C&E) Matrix is a tool used to emphasize importance of Customer Requirements.
Answer
  • True
  • False

Question 27

Question
Relations Diagram, Cause & Effect Diagram, Cause and Effects (C&E) Matrix are generally used in Process Mapping.
Answer
  • True
  • False

Question 28

Question
Statistically, we can do many more potentially useful forms of analysis with continuous data versus discrete.
Answer
  • True
  • False

Question 29

Question
Most processes in the world result in a "Normal" Distribution
Answer
  • True
  • False

Question 30

Question
In a Normal Distribution, roughly 95% of the data are within a distance of HOW MANY standard deviations on either side of the mean.
Answer
  • 1
  • 3
  • 2
  • 6

Question 31

Question
Actual Process Variation is made up of the Observed Process Variation and the Measurement Variation.
Answer
  • True
  • False

Question 32

Question
To address actual process variability, the variation due to the measurement system must first be identified and separated from that of the process.
Answer
  • True
  • False

Question 33

Question
Cost of Poor Quality (COPQ) is a major measurement of the hidden factory. Hidden Factory losses could contribute to what additional percentage of COPQ?
Answer
  • 15-20%
  • 1-5%
  • 5-10%
  • 10-15%

Question 34

Question
Process Mapping is a graphical illustration of the steps of the actual transactional or manufacturing process. A Rectangle is used to show which of the following on a Process Map?
Answer
  • Decision Point
  • Start Point
  • Connector
  • Activity

Question 35

Question
Process Mapping is a graphical illustration of the steps of the actual transactional or manufacturing process. A Rhombus is used to show which of the following on a Process Map
Answer
  • Decision Point
  • Activity
  • End Point
  • Connector

Question 36

Question
Waste is "anything other than the minimum amount of equipment, materials, parts, space, and worker's time which are absolutely essential to add value to the product [or service]." Select the statement that best describes the MOTION type of waste.
Answer
  • Making more or faster than is needed
  • Extraneous, unnecessary actions or having to make repetitive, unnecessary movements
  • Redoing, Reworking, Repairing, or Scrapping the product or service just provided
  • Excessive movement and handling
  • People, material, and machines waiting for one another

Question 37

Question
Workplace Organization or 5S's is:
Answer
  • Spring Cleaning
  • Only to be done in manufacturing
  • A safe, clean, neat, arrangement of the workplace which provides a specific location for everything, and eliminates anything not required
  • Cleaning the facility every time a customer comes
  • Taking key items away from people which are used frequently

Question 38

Question
The phase of 5S (Workplace Organization) when "There should be a place for everything and everything should be in its place" is
Answer
  • Set in order
  • Sustain
  • Shine
  • Standardize
  • Sort

Question 39

Question
Physical Flow is used to give a quick visual representation for the movement of a part or associate (operator). It is also referred to as a Spaghetti Diagram.
Answer
  • True
  • False

Question 40

Question
The phase of 5S (Workplace Organization) when "We Make it the Culture" is
Answer
  • Set in order
  • Shine
  • Standardize
  • Sustain
  • Sort

Question 41

Question
In Eliyahu M. Goldratt's Theory of Constraint concept, a process is faster than its smallest bottleneck.
Answer
  • True
  • False

Question 42

Question
According to The SIX SIGMA WAY, one of the critical elements to the closed-loop business (Six Sigma) system is finding out which X variables have the most influence on the Y variables.
Answer
  • True
  • False

Question 43

Question
The Problem/Opportunity Definition must include a COMPLETE and DETAILED description of the problem that needs to be solved or a potential opportunity that needs to be exploited, and SHOULD also contain causes or solutions.
Answer
  • True
  • False

Question 44

Question
Having well defined Project Boundaries (BEGIN & END points) is not an important aspect of any Lean Six Sigma project.
Answer
  • True
  • False

Question 45

Question
There are three sequential steps in a process. The first pass yield at each step is as follows: Step 1: 90% Step 2: 80% Step 3: 100% The Rolled Throughput Yield (RTY) for this process is:
Answer
  • 270%
  • 90%
  • 72%
  • 100%
  • 80%

Question 46

Question
A Value Stream Map is based on engineering standards or old information.
Answer
  • True
  • False

Question 47

Question
Which of the following is NOT an objective of Values Stream Mapping?
Answer
  • To see across the functional boundaries over which a product's value stream flows
  • To understand the linkage between the information flow and material flow
  • It ties together LEAN concepts and techniques
  • Improves customer response times and customer satisfaction
  • Promotes "cherry picking" and gut feel improvement initiatives

Question 48

Question
The Check (Tally) Sheet tool is used to
Answer
  • Monitor a process against its historical performance
  • Display variable data so that the pattern of variation can be identified
  • Identify relationships between two process variables
  • Provide an easy way to keep track of the frequency of occurrences

Question 49

Question
The Histogram tool is used to
Answer
  • Display variable data so that the pattern of variation can be identified
  • Provide and easy way to keep track of the frequency of occurrences
  • Monitor a process against its historical performance
  • Identify relationships between two process variables

Question 50

Question
The Scatter Diagram tool is used to
Answer
  • Identify relationships between two process variables
  • Provide an easy way to keep track of the frequency of occurrences
  • Display variable data so that the pattern of variation can be identified
  • Monitor a process against its historical performance

Question 51

Question
The Control Chart tool is used to
Answer
  • Monitor a process against its historical performance
  • Identify relationships between two process variables
  • Provide an easy way to keep track of the frequency of occurrences
  • Display variable data so that the pattern of variation can be identified

Question 52

Question
A bi-modal or multi-modal distribution is almost always a sign of a special cause of variation in the process or in the data collection technique.
Answer
  • True
  • False

Question 53

Question
Identify which of these flows is NOT part of a Value Stream
Answer
  • The FLOWCHART
  • The INFORMATION flow
  • The MATERIAL flow
  • The PRODUCTION (TRANSFORMATION) flow

Question 54

Question
For a specific Value Stream, the available time per day is 800 minutes and the Customer Demand is 200 units. Then, the Takt Time at the Pacemaker step is:
Answer
  • 1000
  • 4
  • 0.25
  • 160,000
  • 600

Question 55

Question
The Project Charter should be created as part of the DEFINE phase and remain unchanged for the life of the project.
Answer
  • True
  • False

Question 56

Question
Realistic goals must be SMART. Select the word which is NOT part of what "SMART" stands for.
Answer
  • Aggressive
  • Specific
  • Timely
  • Relevant
  • Attainable
  • Measurable

Question 57

Question
Brainstorming is a way of generating radical ideas.
Answer
  • True
  • False

Question 58

Question
A Pareto Chart proves 80% of the problems cause 20% of the impact.
Answer
  • True
  • False

Question 59

Question
The Control Plan describes the actions required at each step in the process to assure that all process outputs will be in state of control.
Answer
  • True
  • False

Question 60

Question
Visual Management and Workplace Organization (5S) go hand-in-hand.
Answer
  • True
  • False

Question 61

Question
Force Field Analysis specifically can help us determine if a proposed change can get needed support.
Answer
  • True
  • False

Question 62

Question
The correct sequence of the steps in the Dr. Deming's Cycle is
Answer
  • Plan, Do, Check/Study, Act
  • Do, Plan, Act, Check/Study
  • Do, Plan, Check/Study, Act
  • Act, Plan, Check/Study, Do

Question 63

Question
Which company has had the fastest implementation of Six Sigma
Answer
  • Raytheon
  • Honeywell
  • Motorola
  • General Electric
  • Toyota

Question 64

Question
Six Sigma focuses on both the External and Internal Customers
Answer
  • True
  • False

Question 65

Question
The Six Sigma Improvement Methodology helps us identify and reduce/eliminate sources of variation.
Answer
  • True
  • False

Question 66

Question
Which one of James Womack's of LEAN Principles are we required to conduct FIRST?
Answer
  • Continuously improve in pursuit of perfection
  • Identify value stream and eliminate waste
  • Make value flow
  • Specify value in the eyes of the customer
  • Allow the customer to pull

Question 67

Question
LEAN is an umbrella program to create value to the customer by eliminating waste.
Answer
  • True
  • False

Question 68

Question
Variation characterized as normal "bouncing around" of any process is due to which cause?
Answer
  • Special or Assignable
  • Common or Controlled
  • None

Question 69

Question
In the concept of LEAN, SYNCHRONIZATION means
Answer
  • Ready capability to adapt to new, different or changing requirements in time and rate
  • The measure or beat of movement
  • A smooth uninterrupted movement
  • Arrange so that one set of elements exactly equals another
  • To cause to operate with exact coincidence

Question 70

Question
In the "4P" Model of the Toyota Production System, which statement best describes the PHILOSOPHY of the system?
Answer
  • The Heart and Soul of the Toyota Way
  • Add Value to Customers and Society
  • The Dynamic of the Toyota Way
  • Eliminate Waste through Flow and Standardization

Question 71

Question
In the "4P" Model of the Toyota Production System, which statement best describes the PROCESS of the system?
Answer
  • The Dynamic of the Toyota Way
  • Eliminate Waste through Flow and Standardization
  • The Heart and Soul of the Toyota Way
  • Add Value to Customers and Society

Question 72

Question
In the "4P" Model of the Toyota Production System, which statement best describes the PEOPLE and PARTNERS of the system?
Answer
  • Add Value to Customers and Society
  • The Dynamic of the Toyota Way
  • The Heart and Soul of the Toyota Way
  • Eliminate Waste through Flow and Standardization

Question 73

Question
In the "4P" Model of the Toyota Production System, which statement best describes the PROBLEM SOLVING of the system?
Answer
  • Add Value to Customers and Society
  • The Heart and Soul of the Toyota Way
  • The Dynamic of the Toyota Way
  • Eliminate Waste through Flow and Standardization

Question 74

Question
In the Concept of LEAN, FLEXIBILITY means
Answer
  • A smooth uninterrupted movement
  • Ready capability to adapt to new, different or changing requirements in time and rate
  • Arrange so that one set of elements exactly equals another
  • To cause to operate with exact coincidence
  • The measure or beat of movement

Question 75

Question
The focus of Six Sigma is on improving the MEAN of the process under study
Answer
  • True
  • False

Question 76

Question
There is a significant increase in defects when the Sigma number increases
Answer
  • True
  • False

Question 77

Question
Identify the one criterion that is NOT part of the criteria for Project Selection outlined in The SIX SIGMA WAY.
Answer
  • Results or Business
  • Certification
  • Organizational Impact
  • Feasibility

Question 78

Question
Who is considered the "Father of Six Sigma"
Answer
  • Bill Smith
  • Mikel Harry
  • Dr. Edward Deming
  • Jack Welch

Question 79

Question
Who is considered the Creator of the DMAIC Process and Deployment tactics ("Belts")
Answer
  • Dr. Edward Deming
  • Jack Welch
  • Mikel Harry
  • Bill Smith

Question 80

Question
From the list below, identify the one case when an Affinity Diagram is NOT essential.
Answer
  • Facts or thoughts are certain
  • Facts or thought need to be organized
  • Unity within a team needs to be created
  • Ideas need to be clarified
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