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LEAN SIX SIGMA BLACK BELT TEST QUESTIONS AND ANSWERS
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LEAN SIX SIGMA BLACK BELT TEST QUESTIONSAND ANSWERS
PDCA - ANSWER Plan, Do, Check, Act
The term "Six Sigma" refers to. - ANSWER The ability of highly capable
processes to produce output within specification. In particular, processes that
operate within Six Sigma quality produce a defect level below 3.4 defects per
(one) million opportunities (DPMO).
Six Sigma has two key methodologies - ANSWER DMAIC & DMADV (both
inspired by W. Deming's Plan, Do, Check, Act cycle)
EXISTING PROCESS OR BUSINESS
- DMAIC (Define, Measure, Analyze, Improve, Control)
NEW PRODUCT OR PROCESS
- DMADV (Define, Measure, Analyze, Design, Verify)
Define (DMAIC) - ANSWER The process improvement GOALS that are
consistent with customer demands & enterprise strategy.
First asks leaders to define core processes. The selected project scope,
expectations, resources & timeliness need to be defined.
,Identifies specifically what is part of the project & what is not, & explains the
scope of the project.
Many times the first passes at process documentation are at a general level.
Additional work is often required to adequately understand & correctly
document the processes.
Measure (DMAIC) - ANSWER The current process & collect relevant data for
future comparison.
Six Sigma approach asks the Black Belt project manager to quantify &
benchmark the process using actual data. at a minimum consider the mean or
average dispersion or variation (maybe, even calculate the standard deviation).
Trends & cycles can also be very revealing. Process capabilities can be
calculated once there is performance data.
An Analyze (DMAIC) - ANSWER To confirm the relationship and causality
of factors. Identify what the relationship is & try to make sure all factors have
been accounted for.
Once the project is understood & the baseline performance documented &
verified that there is real opportunity, it is time to do the analysis of the process.
Statistical tools are applied in this step to validate root causes of problems. Any
number of tools & tests can be used.
The objective is to understand the process at a level, sufficient to be able to
formulate options for improvement. We should be able to compare the various
options with each other to determine the most promising alternatives.
, Superficial analysis & understanding will lead to unproductive options being
selected, forcing recycle through the process to make improvements. At the
other extreme is thorough analysis of only a few activities.
Improve (DMAIC) - ANSWER Or "Optimize" the process based upon the
analysis using techniques like "Design of Experiments".
During this phase, ideas & solutions are put to work. The Black Belt has
discovered & validated all known root causes for the existing opportunity.
Approach requires Black Belt to identify solutions. There must be checks to
assure that the desired results are being achieved. Of course some experiments
& trials may be required in order to obtain best solution. While doing so, it is
necessary to make all the project associates know that these are trials and
actually are part of six sigma methodology.
Control (DMAIC) - ANSWER To make sure any variances are caught and
fixed before they become defects. Establish pilot runs to determine "process
capability", move into full production & continue to measure the process &
implement control mechanisms.
Most people think the best performance you ever can get from a process is at
the very beginning. Over time, there is an expectation that things will slowly get
a little worse until it's time for another major effort toward improvement.
Contrast this with the Kaizen approach, which looks to make everything
incrementally better on a continuous basis.
The sum of incremental improvements can be quite large.
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