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Six Sigma Green Belt Certification Test. Time: 2 hours Marks: 50

The Question paper is given to you in word document as a softcopy. Please enter your name on the Top left hand Corner. The Question paper has 3 sets of Questions. All Questions are Compulsory. Set 1 is Multiple Choice. You need to change the color of the right answer to green and save the file. It has 22 Questions each of 1 mark. There is no negative marking. Set 2 is Short Answers. It has 2 Questions of 6 marks each. You need to insert your answers after each question and save the file. Set 3 is analysis and has 1 Question of 16 marks. You need to insert your answers after the question and save the file. Note please copy analysis / graphs and any other thing that you deem fit from your Minitab analysis, onto this word document to support your answers. Also pen the same in your answers sheets hard copy. Set one needs to be answered on the Question paper itself. Set 1 Multiple Choice 1. A team has been asked to reduce the cycle time for a process. The team decides to collect baseline data. It will do this by A. seeking ideas for improvement from all stakeholders B. researching cycle times for similar processes within the organization C. obtaining accurate cycle times for the process as it currently runs D. benchmarking similar processes outside the organization 2. A Six Sigma project designed to solve a particular problem needs a definition/scope statement to help avoid: A. going beyond the problem into other problems B. failing to cover the entire problem C. misunderstanding and disagreement between team members regarding problem boundaries D. all of the above E. none of the above

000.5 B. Which one of the following is true ? A. Then DPU =_____ A.To calculate mean and s. The payroll department collects 328 cards and finds a total of 87 defects. To identify cause and effect relationship B. median C. (87x1. none of the above . In Box plot. There are 14 different defects that can occur on a completed time card. none of 11. There are 14 different defects that can occur on a completed time card. two standard deviations on each side of the mean would include approx what percentage of the total population? A. none of the above 7. 87/14 D. The mean. mode D. it is normal C.3. ZST = ZLT C.000)/(14x328) 5. 99% E. the inside horizontal line describes the A. USL = 490 gms and LSL = 510 gms D. USL = 510 gms and LSL = 490 gms C. USL = 497 gms and LSL = 503 gms 6. 47% B. USL = 506 gms and LSL = 494 gms B. it is exponential B. Then DPMO =____ A. Which of the following is true A. Which is true? A.88 signifies – A. 87/(328x14) C. Cp.5 D. 87/328 B. What can be said about the distribution: A. ZST = ZLT + 1. 95% D. None of the above 9. it is poison D. For a manufacturer making tetrapacks. 88% of the variation in X is explained by variation in Y B. Cpk are not comparable D. The payroll department collects 328 cards and finds a total of 87 defects. 12% of the variation in X is explained by variation in Y D. median and mode of a distribution have the same value. 68% C. 88% of the variation in Y is explained by variation in X 10. Cp < Cpk the above C.000. In regression analysis. To identify vital few from trivial many C. The machine is able to produce packs with a mean of 500 gms and a standard deviation of 1gm. 87/14 D.000)/(14x328) 4. (87x1.d. mean B. R² = 0. For a normal distribution. ZLT = ZST + 1. none of the above(unimodal) 8. Pareto diagram is used: A. 87/(328x14) C. 87/328 B. D. Cp >= Cpk B. none of the above 12. 12% of the variation in Y is explained by variation in X C. the customer is willing to accept the product only if it weighs between 490 gms and 510 gms.

(USL-LSL)/() D. Chance Causes B. 4 D. Which of the following is true? A. 50. All the non. 8 B. We know that 68. Delays can always be eliminated 22. (Mean-LSL)/(6*) B. 60. Measurement uncertainty is known and suitable if A. Project title D.5 kg & Mode is 37.9 kg. None of the above 14. assignable causes C.26% of the pouches weigh between 196 kg and 204 kg. Median is 60 kg & Mode is 20 kg 19. Chance & assignable causes D. Which of the following is true? A.5 kg & Mode is 30 kg B. Median is 37. Which of the following is likely to be the standard deviation of the distribution? A. Variation in a process exists due to A. All the activities in the TO BE map need not necessarily be value -adding activities D. Run chart D.5 kg D. Their weights in kgs are as follows: 20. Mean is 37. 30. The weight of the pouches of a particular product is normally distributed with a mean of 200 kg. The process capability is defined by the formula A. Mean is 39. There is a group of 10 students in a class. It happens without any causes 15. %R&R = 50% B. Fatal modes for Electrical Assemblies. 45.(USL-LSL)/(6*) C. Failure Mode and Effect Analysis B.value adding activities can be eliminated B.13. Tools to be used 17. 16. 5 20. CTQs are derived from A. All the processes in the TO BE map should be value-added activities C. Project scope B.9 kg. Mean is 39. FMEA stands for A. 56. Median is 39. 56. %R&R <= 10% C.5 kg. Which of the following are not included in the project charter A. Histogram B.9 kg & Mode is 30 kg C. Median is 37. 30. (USL-LSL)/(3*) 21. 22. %R&R >30% D. Which of the following hold true for Normal Distribution? . Pareto diagram 18. 30. Failure Model for Effectiveness Analogy D. Mean is 30 kg. Failure Mode and Efficient Analysis C. Project goal C. VOC C. 2 C.

execution aborted.1 23. Commercial use of the Software is prohibited.5 22. The Performance output of 4 operators was measured and the same is given below.A.47% Individual 95% CIs For Mean Based on Pooled StDev ---------+---------+---------+---------+ (---------*---------) (--------*-------) (--------*---------) (---------*--------) ---------+---------+---------+---------+ 21.0 25.429 0.238 1.2 Operator 4 23.15 15. Operator 1 21.350 StDev 0. Executing from file: C:\Program Files\Minitab\Minitab 16\English\Macros\Startup.6 22. Operator3.2 21. All of the above Set 2 Short Answers 1 . It is a Bell shaped Curve D.4 23.ANOVA Method * ERROR * Design is not balanced.2 24. One-way ANOVA: Operator1.8 Operator 3 20.860 21.830 1.5 20. Gage R&R Study .14% R-Sq(adj) = 16.4 ppm or virtually Zero Defect C.2 23. Operator 2.2 Level Operator1 Operator 2 Operator3 Operator 4 N 4 5 4 4 Mean 22.5 22.2 Operator 2 22.1 21.8 24.650 23. A normally distributed process has only 0.2 22.0 ————— 01-09-2013 14:55:16 ———————————————————— Welcome to Minitab.10 22.5 it denotes 3.mac This Software was purchased for academic use only.156 S = 1.0000002% parts outside the +/.7 24.05 P 0.7 23.1.6 limits B.16 F 2.075 22.1 23.25 MS 2. Operator 4 Source Factor Error Total DF 3 13 16 SS 7.38 1. Taken along with a long term mean shift of +/.078 R-Sq = 32.507 Pooled StDev = 1.078 . Check using ANOVA if performance of operators is equal or Not. press F1 for help.

Operator 4 .075 22.05 P 0. Operator 2. Operator 4 Source Factor Error Total DF 3 13 16 SS 7.507 Pooled StDev = 1.830 1. Operator3.429 0.078 R-Sq = 32. Operator 2.238 1.2 Level Operator1 Operator 2 Operator3 Operator 4 N 4 5 4 4 Mean 22.15 15.650 23.078 Individual Value Plot of Operator1.16 F 2.350 StDev 0. Operator 4 Boxplot of Operator1.6 22. Operator3. Operator 2.860 21.10 22.47% Individual 95% CIs For Mean Based on Pooled StDev ---------+---------+---------+---------+ (---------*---------) (--------*-------) (--------*---------) (---------*--------) ---------+---------+---------+---------+ 21. Operator 4 One-way ANOVA: Operator1.25 MS 2. Operator 4 Boxplot of Operator1.14% R-Sq(adj) = 16. Operator 2. Operator3.38 1. Operator 4 Residual Plots for Operator1.Individual Value Plot of Operator1.156 S = 1. Operator3.8 24. Operator 4 Residual Histogram for Operator1. Operator3. Operator 2. Operator 2. Operator3. Operator3. Operator 2. Operator 4 Normplot of Residuals for Operator1. Operator3. Operator 2.0 25.

Normal Probability Plot (responses are Operator1. Operator 4) 99 95 90 80 70 60 50 40 30 20 10 5 1 Percent -2 -1 0 Residual 1 2 Individual Value Plot of Operator1. Operator3. Operator 4 25 24 23 Data 22 21 20 Operator1 Operator 2 Operator3 Operator 4 . Operator 2. Operator 2. Operator3.

xlsx” . Operator 4 25 24 23 Data 22 21 20 Operator1 Operator 2 Operator3 Operator 4 Histogram (responses are Operator1.5 -1.0 1.0 -0.5 2. Operator 2. Operator3.0 2.Boxplot of Operator1.0 0.5 Residual 1.5 0. Operator 4) 5 4 Frequency 3 2 1 0 -1. Draw a Cause & Effect Diagram using Mintab for the data given in file “Cause & Effect Data. Operator 2. Operator3.

Draw graphs/ charts where necessary.Cause-and-Effect Diagram Measurements Material Personnel Training Scale Age Experience Motivation Courtesy Technique Amount Lighting Up to date Order Age pe m Te Or The data of Electricity interruptions in given in the file “Electricity Interruptions Reasons. Which interruptions will you address in priority and why. Set 3 Analysis Analyze the data given in the file “Oil Bottle Data.xlsx”.xlsx” using Minitab and give your inferences. Stat >BasicStatistics> Normality Test>Select Oil>Ok id m Hu it y er pp ra W s xe Bo r te in Pr Environme nt r tu ra e Humidity Power Consistency Procedure Cleanliness Maintence Methods Machines .

Employee Main Effects Plot for Oil Data Means Branch 224 222 220 Shift Mean A B 1 2 Study hour 224 222 220 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 Employee 6 7 8 9 10 11 12 Split Worksheet Branchwise .005 Hence Data is non normal Stat>ANOVA>Main Effects Plot>Response:Oil.1 Mean 220.621 N 240 AD 3.05 We reject Ho as p value is <0.322 P-Value <0. Study Hour.9 99 95 90 80 70 60 50 40 30 20 10 5 1 0.005 Percent 210 215 220 225 Oil 230 235 240 Ho: Data is normal P-value is the prob that data is normal We reject Ho when p value is < .Probability Plot of Oil Normal 99.9 StDev 3. Factors:Branch. Shift.

9 99 95 90 80 70 60 50 40 30 20 10 5 1 0.05 in both cases hence we reject Ho and conclude data is non normal in both cases Main Effect Plot for Branch A .640 P-Value <0.6 StDev 3.005 Percent 210 215 220 225 Oil 230 235 Branch A Probability Plot of Oil Normal 99.591 N 120 AD 2.1 Mean 222.010 Percent 210 215 220 Oil 225 230 Since p value is <.025 0.1 2.9 99 95 90 80 70 60 50 40 30 20 10 5 1 0.1 Mean StDev N AD P-Value 219.697 120 1.Branch B Probability Plot of Oil Normal 99.

5 225.0 222.0 227.5 220.5 220.0 222.0 Study hour Mean 1 2 Employee 230.0 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 1 2 1 3 14 1 5 1 6 1 7 18 19 20 \ Looks affected by EMPLOYEE 6 Subset Worksheet of Branch A excluding employee 3 and only employee 3 .0 227.Main Effects Plot for Oil Data Means Shift 220 218 216 Study hour Mean 214 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Employee 220 218 216 214 1 2 3 4 5 6 7 8 9 10 11 12 Looks affected by EMPLOYEE 3 BRANCH B Main Effects Plot for Oil Data Means Shift 230.5 225.

672 Percent 205 210 215 Oil 220 225 Here p value is > 0.6 2.856 10 0.135 110 0.178 0.247 0.05 in both cases hence we fail to reject null hypothesisand conclude data is normal in both cases Process Capability of Branch 1 without Employee 3 .1 Mean StDev N AD P-Value 219.Branch A excluding employee 3 Normality Test Probability Plot of Oil Normal 99.917 Percent 212 214 216 218 220 Oil 222 224 226 Subset worksheet of Branch A only employee 3 Probability Plot of Oil Normal 99 95 90 80 70 60 50 40 30 20 10 5 1 Mean StDev N AD P-Value 214.9 99 95 90 80 70 60 50 40 30 20 10 5 1 0.5 3.

W ithin Performance PPM < LSL 2.10543 StDev(Overall) 2.1352 USL W ithin Overall Potential (Within) Capability Cp 1.39 * 208 Observed Performance PPM < LSL 100000.37 Exp.22 PPM Total 121363.65 Cpk 1.00 PPM > USL 0.51 Overall Capability Pp PPL PPU Ppk Cpm 1.85554 USL W ithin Overall Potential (Within) Capability Cp 1.14 WE see that process capability of Branch A excluding employee 3 is far better than that of Branch A Employee 3 only Hence Employee 3 must be “fixed” (Trained) .63 1.51 CPU 1. W ithin Performance PPM < LSL 40749.49 1.49 * 210 Observed Performance PPM < LSL 0.91 PPM > USL 29.25 Process Capability only Employee 3 Branch A Process Capability of Oil LSL Process Data LSL 210 Target * USL 230 Sample Mean 214.29 CPL 0.56 1.36 PPM Total 3.86 0.58 Overall Capability Pp PPL PPU Ppk Cpm 0.00 213 216 219 222 225 228 Exp.00 PPM Total 0. Overall Performance PPM < LSL 3.74 PPM > USL 0.34 0.58 CPU 2.00 PPM Total 100000.39 1.37 PPM > USL 0.00 PPM Total 40749.565 Sample N 110 StDev(W ithin) 2.77 PPM > USL 0.13 Exp.00 212 216 220 224 228 Exp.5858 StDev(Overall) 3.58 CPL 1.00 Cpk 0.Process Capability of Oil LSL Process Data LSL 210 Target * USL 230 Sample Mean 219.51 PPM Total 4. Overall Performance PPM < LSL 121333.505 Sample N 10 StDev(W ithin) 2.00 PPM > USL 0.

9 2.748 0.703 110 0.050 Percent 215 220 Oil 225 230 Only Employee 6 .1 Mean StDev N AD P-Value 221.Marginal Plot of Oil vs Employee 235 230 Oil 225 220 215 210 0 2 4 6 8 Employee 10 12 Branch B excluding employee 6 and only employee 6 Branch B excluding employee 6 Normality Test Probability Plot of Oil Normal 99.9 99 95 90 80 70 60 50 40 30 20 10 5 1 0.

00 1.70298 USL W ithin Overall Potential (Within) Capability Cp 1.47 1.04 Cpk 1.23 1.6 2.89 Only Employee 6 .00 PPM > USL 9090. W ithin Performance PPM < LSL 2.Probability Plot of Oil Normal 99 95 90 80 70 60 50 40 30 20 10 5 1 Mean StDev N AD P-Value 230.0 Oil 232.919 Sample N 110 StDev(W ithin) 2.04 Overall Capability Pp PPL PPU Ppk Cpm 1.00 * 210 Observed Performance PPM < LSL 0.91 213 216 219 222 225 228 231 Exp.0 227.674 0. Overall Performance PPM < LSL 5.5 235.13 Exp.72 PPM Total 1401.26 PPM > USL 937.0 237.05 hence we fail to reject null hypothesis and conclude that data is normal in both the cases Process capability index Without Employee6 Process Capability of Oil LSL Process Data LSL 210 Target * USL 230 Sample Mean 221.91 PPM Total 9090.18 PPM > USL 1396.53 CPU 1.28 CPL 1.5 230.59898 StDev(Overall) 2.383 10 0.87 PPM Total 940.5 P value is >.054 Percent 225.

40 PPL 2.Process Capability of Oil LSL Process Data LSL 210 Target * USL 230 Sample Mean 230. Overall Performance PPM < LSL 0.00 PPM > USL 400000.00 PPM > USL 595758.10 Overall Capability Pp 1.38343 USL W ithin Overall Potential (Within) Capability Cp 1.00 PPM Total 400000.08 Ppk -0.79 CPL 3.86072 StDev(Overall) 2.578 Sample N 10 StDev(W ithin) 1.88 PPU -0.10 Cpk -0.86 Exp. W ithin Performance PPM < LSL 0.08 Cpm * 212 Observed Performance PPM < LSL 0.00 PPM > USL 621898.00 216 220 224 228 232 236 Exp.02 WE see that process capability of Branch B excluding employee 6 is far better than that of Branch A Employee 6 only Hence Employee 6 must be “fixed” (Trained) Marginal Plot Marginal Plot of Oil vs Employee 235 230 Oil 225 220 215 210 2 4 6 8 Employee 10 12 .02 PPM Total 595758.69 CPU -0.86 PPM Total 621898.

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