Six Sigma Green Belt-Value of Six Sigma
Exam Questions with Correct Answers
What does DMAIC stand for - Answer-Define, Measure, Analyze, Improve, Control
Define - Answer-Covers the project Charter, customer needs and requirements and
process mapping
measure - Answer-describes how to identify the right thing to measure, how to create a
plan to collect that data, and how to baseline the process
analyze - Answer-explain how to come up with a long list of possible root causes to a
problem, narrow that list down to a short list and then isolate it to one or two root causes
Improve - Answer-describes how you can improve that condition
Control - Answer-explores how you can maintain the improved process
Six Sigma Culture - Answer-Successful six sigma is more than analysis of variance,
design of experiment or regression analysis. If our culture is not six sigma ready the
competent use of statistics will npt be enough for a projects success
Value Add Rule 1 - Answer-Is critical to six sigma/ value has to change the form or
function. hamburger from raw to cooked inedible to edible( transporting beef from farm
to restaurant did not add value. factory two parts put together adds value, measuring
them doesn't
Value Add Rule 2 - Answer-customer must be willing to pay for it- put $3.00
cheeseburger in a gold box, it's now $300.00 easy to transport - changed function but
client does not want to pay for it. do not add value
Value Add Rule 3 - Answer-Get it right the first time- ER run 10 lab tests in an hour but
did 5 incorrectly. now have to pay twice as much to get those 5 corrected also caused
back up in ER
Waste - Answer-Not adding value it is waste
Eight Types of waste 8 types of waste - Answer-Remember by using the word
DOWNTIME-Defects, Over Production, waste, Non-utilized talent, transportation,
Inventory, Motion, Extra Processing
Defects - Answer-anytime you make a mistake and have to complete the work again
,Over production - Answer-when you produce more than you need or you deliver
something sooner than needed-waste not changing form or function and need
somewhere to store it
Waiting - Answer-huge waste-not changing form or function when you wait for
something. waiting in line , waiting for mail
Non-Utilized Talent - Answer-Underemployed or over employed
Transportation - Answer-Moving things, changing location, but not changing products
form or function
Inventory - Answer-excess inventory waste storing cost money and space, also if
something happens to stored inventory, you will have defective products which are also
waste
Motion - Answer-Form of waste if you spend more time looking for an object to do your
job, you spend less time doing your job.
Extra Processing - Answer-If you inspect a product three times and it was perfect the
second time, then you are wasting your time, not adding value to the product
Defects are - Answer-Mistakes, Flaws, Customer complaints , Warranty returns, liability
exposure , all non quality items
Six Sigma - Answer-A measure of quality that strives for near perfection. Improving
Processes- engaging in war on defects and slow- It's a discipline, data driven approach
and methodology for eliminating defects. Reducing companies number of defects to 3.4
defects for every million opportunities began 1985
Foundations needed to eliminate waste - Answer-The quality improvement side and the
speed improvement side
CPR - Answer-consistent , predictable and repeatable
Good enough is not good enough - Answer-shooting for target with as little variation as
possible around those targets
Cost of -Poor Quality - Answer-25-30% of annual revenue is lost to it
Cost of Poor Quality- Internal Failures - Answer-Accidents, work arounds, quick fixes,
scrap, rework, defects, mistakes employee turnover, equipment downtime, sorting
Cost of Poor Quality- External Failures - Answer-Customer complaints, Penalties,
liability suits, repair costs, time spent evaluation things gone wrong and responding to
upset customer
,Cost of Poor Quality- Appraisal Cost - Answer-Audits, testing, Inspections, equipment
calibration
Cost of Poor Quality Prevention Costs - Answer-Error Proofing, Capability studies,
Procedure writing, applicant screening, education and training
Tracking Costs Over Time - Answer-prevention cost goes up at 1st then levels out don't
get caught up in numbers 5% is great
Joseph Juran - Answer-to reach a solution two journeys one is a diagnostic journey
from symptom to cause and the other is from cause to remedy. easier is from cause to
remedy bc if we find the right cause the solutions tend to gravitate toward the cause. Go
through cause gate
How many types of data - Answer-2 Attribute ( discrete data) & variable data
Attribute data(discrete data) - Answer-Qualitative in nature- only two out comes yes or
no , pass or fail , a go or no go can be categorized in classifications, and we can then
count how many show up in each one of the classes # of defects can't divide in 1/2
doesn't make sense
Variable data - Answer-Quantitative in nature, what we measure, continuous data
measured over a continuum can divide in 1/2 makes sense
Example of Attribute data - Answer-people can't have 8 1/2 people at an event-Yes/No
Questions
Example of Variable data-continuous data - Answer-speed, pressure, time, feed rates
Descriptive Statistics - Answer-describe what data looks like
Measures of location - Answer-Measuring the mean median or mode of the data set
also called central tendencies
measures of variation - Answer-spread of data dispersion-use the range, interquartile
range, standard deviation, or variance to
Standard deviation (measure of variation) - Answer-the distance from the mean
Hypothesis testing (How you test ) - Answer-used when making inferences about what
our data is telling us. helps integrate the voice of the process with the voice of the
business. (use statistical difference with hypothesis testing)-concept ;use different
testing sample T test ex can use to test for variance.
, Statistical Difference (measure of variation) - Answer-a difference or change in the
process that probably didn't happen by chance. we are looking for statistical differences
when using hypothesis testing
Practical Difference - Answer-take into consideration- stats may show one thing but is
that best/practice for your company always make sure you understand your decision
and it's not based on stats alone
Define Phase - Answer-problem is initiated, defined, goals and scope identified as well
as customer, project charter is developed based on real life problem effects customer,
business case is defined, benefits are determined by asking basic questions, Project
management is determined including the plan, stakeholder, management support and
teams. need final approval to move forward and ensure success (sponsor)
Measure Phase- - Answer-measurement systems are developed and evaluated/current
process performance is measured, key performance indicators are determined, data is
collected quality of data is checked for accuracy, distribution of data can be determined
to see how the process is behaving the amount of defects and variation present are
determined-when and where to gather data from and what should be used
Analyze Phase - Answer-Potential causes of a problem are identified. Current
processes are analyzed, relationships bt inputs, processes and outputs are identified,
data analysis is carried out, waste and root causes are determined, root causes are
verified to understand cause and effect.great deal of brainstorming , data analyzed to
show trends, use multiple tools to judge accuracy of data from a statistical point of view
Improve Phase - Answer-All potential solutions are evaluated through data-driven
exercises so that assumptions are mitigated, error proofing exercises are put into place
to eliminate accidents , risks are assessed, failure modes and effects analysis is
performed, pilot plans are conducted to ensure proper roll out before implementation
occurs, implementation occurs, validation of stat methods takes place-generation of
solutions occurs-best solutions selected based on critrea of business feasibility
Control Phase - Answer-Finalized control systems are determined and long-term
capabilities are verified for sustainable and long term success. Import to understand
how the process will cont. to be measured after implementation. this is performed
through statistical process control and control plans that determine exactly who and
what should be measured. Standard processes are put in place so that the old way of
doing things does not happen again. Improvements are quantified to make sure the
goals of the project were actually achieved
Project Closeout - Answer-most important close out with clear reports and actions and
best practices should be documented for all the lessons learned. Successful project
should end with a celebration
