ISE 420 – Process Improvement Methods -Exam 1

April 13, 2010

Name:__________________________________________________ Number:______________________

The following test determines the understanding of the principles of Lean 6-Sigma and its
associated tools. Please provide the most appropriate choice in the selection available.

This exam is two parts. Part I consists of True and False questions, and Part II is a
multiple choice part. Choose the best choice possible. Exam duration is a maximum of two
hours. The exam is open books and notes. Total points in this exam are 100 points plus 6
extra credit points. The exam cannot be copied or distributed and answers should be given
on the same test sheets.

Signature_______________
Part I – True or False Questions – 22 Points

1. Common Cause Variation is the variation that cannot be removed unless we redesign the
process.
True False

2. Special Cause Variation are those causes that can be found, but not necessarily corrected

True False

3. If a process is normally distributed, then we expect that 99.73% of the observations to fall
within three sigma from the mean.
True False

4. It is far more difficult to treat Special cause variation than that of Common Cause variation

True False

5. In a Lean Six Sigma working framework, statistical Control Limits and Specification Limits
are essentially the same
True False

6. The Mean, Mode, and Median are equal when we have a normal distribution.
True False

7. The 6-Sigma DMAIC model stands for Design, Measure, Analyze Improve, and Control
True False

8. The central limit theorem assures that, as the sample size increases, the distribution of sample
means is approximately normal.
True False

9. Six Sigma has not created new tools, it has simply organized a variety of existing tools to
create flow.
True False

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ISE 420 – Process Improvement Methods -Exam 1
April 13, 2010

Name:__________________________________________________ Number:______________________

10. A 99% Quality is equivalent to about 3.8 Sigma Level quality.

True False
11. waste is anything other than the minimum amount of time, material, people, space, energy,
etc… needed to add value to the product or service you are providing.
True False

Part II – Multiple Choice Questions - Circle your choice clearly – 80 Points

1. As 6-Sigma Green Belt, your role is:

a) Assist project champions and Black Belts in Identifying and Scoping Problems
b) Collect appropriate data for project analysis and process improvements
c) Work with process owners to implement improvements
d) All the above

2. 6-Sigma Project Charter does not include:

a) Project Scope, Goals and Objectives
b) Team members or leadership
c) Initial project timing
d) Who is the customer
e) Cause and effect matrix

3. 6-Sigma DMAIC problem solving Model places emphasis on:

a) Statistical thinking and tools applied on collected data based on specific plan
b) Quality management tools
c) Process steps and outputs
d) Benchmarking and knowledge of subject matter experts

4. 6-Sigma process analysis for optimization or control focuses on:

a) Statistical analysis
b) Quality management tools
c) Measuring and analyzing process inputs
d) Outputs to eliminate defects

5. Benchmark performance according to 6 Sigma is:

a) Large size companies
b) Companies that are in manufacturing industries
c) Service industry companies
d) World Class Performance

6. 6-Sigma defect is defined as:

a) The Green Belt is not performing well
b) The Black Belt is not performing well
c) The project Champion or the Process Owner are not satisfied with the results
d) The output or results do not mach people expectations
e) Occurrence where performance does not meet a standard or specification

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ISE 420 – Process Improvement Methods -Exam 1
April 13, 2010

Name:__________________________________________________ Number:______________________

7. In 6-Sigma, Y=f(x) describes

a) Output as a function of various inputs
b) Mathematical relationship
c) Statistical relationship
d) Any relation between process and design

8. A Good metric or Measure

a) Reflects the language of the customer
b) Determines the ability to set up processes
c) Drives appropriate actions and analysis
d) Can be expressed in attribute data form

9. When examining data, critical to look at

a) Time data was collected
b) Measurement system capability
c) Representation of the process being studied
d) All of the above

10. Four stages of process mapping are:

a) Plan, Do, Analyze, and Check
b) Current, Ideal, Possible, Future
c) Value, Waste, Customer, Time
d) Think, Reality, Should, Could

11. When we optimize process/design performance, the first step is:

a) Define the scope of the problem
b) Reduce variability
c) Complete a concept/system/process/design study
d) Adjust the process/design performance to its intended target

12. When we optimize process/design performance, the second step is:

a) Reduce variability
b) Complete a concept/system/process/design study
c) Define the scope of the problem
d) Adjust the process/design performance to its intended target

13. As a Green Belt monitoring coating thickness, what action should be taken when finding a
special cause?
a) Determine the person responsible for the process
b) Call for a meeting
c) Determine the reason for the special cause
d) Write a report to management indicating personnel failure to handle the process

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ISE 420 – Process Improvement Methods -Exam 1
April 13, 2010

Name:__________________________________________________ Number:______________________

14. What should you do if the data you are analyzing (say for coating process capability analysis)
is not normally distributed?:
a) Ignore the issue and continue with analysis
b) Try a data transformation to convert data to normality
c) Use Weibul Analysis
d) Call the Black Belt responsible

15. In a 6-Sigma process with only Upper Specification Limit, USL=100, Sigma=10, Xbar = 87,
calculate the Z-value or Z-Score:
a) 1.3
b) 1.6
c) 1.15
d) None of the above

16. With answer from above, what is the probability of defect (crossing the upper specification
limit – Use tables)
a) 0.0968
b) 0.07
c) 0.12
d) None of the above

17. These are metrics that we use in Six Sigma. Select what applies.
a) Defects
b) Defects per unit (DPU)
c) Parts per million (PPM)
d) Defects per million opportunities (DPMO)
e) Rolled Throughput yield (RTY)
f) First Time Yield (FTY)
g) Sigma (s)

18. Convert 3000 PPM to a Long Term Z value using table

a) 2.75
b) 3.75
c) 4.5
d) 1.9

19. Check the blank that applies

• Lean
– Relentless elimination of all waste
– Creation of process flow
– Resource optimization
• Six Sigma
– Focus on voice of the customer
– Decisions are made based on facts and data
– Variation reduction to near perfection levels

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ISE 420 – Process Improvement Methods -Exam 1
April 13, 2010

Name:__________________________________________________ Number:______________________

20. In a three steps process the RTY for step 1 is 0.6 0r 60%, the RTY for step 2 is 0.7 and
the RTY for step 3 is 0.8. The RTY for the total process is:
a) 2.1 %
b) 0.1 %
c) 33.6%
d) None of the above

21. In the RTY example above, assume the cost of repair or rework for step 1 is $50, 000, for
step 2 is $50,000, and for step 3 is $ 100,000. To minimize losses, you would focus first on
improving:
a) Step 1
b) Step1 and 2
c) Step 3
d) Step 2
e) None of the above