Questions

1. If the number of runs required to perform a full-factorial experiment is too costly, the CSSBB, needing to have the same number of variables but fewer runs, should chose: A. Fractional factorial. B. Multilevel factorial. C. Replicated factorial. D. Completely randomized factorial.

2. Which of the following is used extensively in quality function deployment (QFD)? A. Matrix diagram. B. Affinity diagram. C. Cause and effect diagram. D. Activity network diagram.

3. A change agent is responsible for helping the organization do which of the following? A. Reorganize departments. B. Determine performance criteria. C. Overcome the fear of the unknown. D. Identify which group is responsible for resistance.

4. Internal failure costs are best described by which of the following? A. The opposite of external failure costs. B. The economic costs associated with a catastrophic failure of an internal subsystem. C. The costs resulting from a nonconformance detected before a product or service is provided. D. The unavoidable quality system costs associated with the manufacture of any product or service.

5. Which of the following approaches is most important in evaluating and understanding design intent? A. Developing FMEA. B. Brainstorming failure modes. C. Conducting computer simulations. D. Identifying the functional requirement.

6. Cycle time is: A. the amount of time required to complete a process. B. material that has begun the process but not completed it. C. the amount of time required to complete one cycle. D. the amount of time performing activities that the customer is willing to pay for. E. the amount of time to convert from making one product to making a different one. F. the result of dividing the time available by the number of units to be produced. G. material waiting to be processed.

7. Which of the following is the best description of the purpose of using control charts? a. Detect the causes of non-conformances. b. Determine how to recreate the process. c. Evaluate process performance over time. d. Determine if the process is performing within specifications.

8. Which of the following control charts is most appropriate if monitoring the number of defects with varying sample sizes? a. u. b. np. c. c. d. p.

9. Which of the following is defined as continuous, incremental improvement? a. JIT. b. Kaizen. c. Kanban. d. Kaikaku failure

10. To identify waste or non-value-added activities, a CSSBB would be best advised to use which of the following tools? a. Scatter diagram. b. Pareto analysis. c. Value Stream Mapping. d. Fishbone Diagram.

11. The most important aspect of functional requirements is that they can: a. Describe a single, measurable performance. b. Be traceable to the voice of the customer. c. Provide upper and lower performance limits. d. Describe how a product or service should operate.

12. A six-sigma team efforts resulted in the installation of a system that prevents orders with incorrect information from being forwarded to scheduling. The best description of this lean improvement tool is: a. Kanban. b. Kaizen. c. Poka-yoke. d. Standard work.

13. A black belt is developing a FMEA for the food preparation in a fast-food restaurant. The following ratings were determined for the low-heat temperature failure mode. Severity = 9 Occurrence = 2 Detection = 1

What risk priority number should the black belt determine from this FMEA? a. 4. b. 6. c. 12. d. 18.

14. The technique which can significantly shorten changeover time is: a. SMED. b. Standard work. c. Poka-yoke. d. Continuous flow.

15. A measurement system analysis (MSA) is designed to assess the statistical properties of which of the following? a. Gage variation. b. Process stability. c. Process performance. d. Engineering tolerances.

16. A six sigma project to reduce billing statement expenses has shown the need to hire two additional mailroom clerks. Based on this information, which of the following metrics should be used to measure the financial benefits of the project? a. Net present value (NPV). b. Cost of poor quality (COPQ). c. Return on investment (ROI). d. Internal rate of return (IRR).

17. Which of the following terms is used to describe the risk of a type I error in a hypothesis test? a. Power. b. Beta risk. c. Level of significance. d. Confidence level.

18. In comparison to a full-factorial design of experiment (DOE), a traditional, one-factor-at-a-time (OFAT) approach will: a. Save time. b. Cost less. c. Miss interaction. d. Gain efficiencies.

19. Forming, Storming, Norming and Performing are each terms that describe which of the following? a. Stages of team growth. b. Brainstorming process steps. c. Root cause identification and corrective action. d. Process variation reduction and improvement phases

20. An important aspect of data collection is that the data collector should: a. Use a stratified sampling plan. b. Know how the data are to be used. c. Determine the dispersion of the data. d. Use a control chart to analyze the data.

21. In gage R & R studies, reproducibility refers to which of the following? a. The variation in measurements obtained when one measurement device is used several times by the same person. b. The variation in measurements obtained by different people using the same measurement device. c. The variation in measurements obtained when different devices are used several times by the same person. d. The variation in measurements obtained when different devices are used several times by different people.

22. Quality function deployment is a tool to aid in: a. Analyzing non-paired data. b. Linking customer requirements to product features. c. Ascertaining which processes are functioning correctly. d. Determining if quality procedures are being followed on the shop floor.

23. Which of the following techniques should a team use to obtain a large number of possible reasons for excess variation in a dimension? a. Pareto chart. b. Flowchart and process map. c. Cause and effect diagram. d. Relationship matrix.

24. Which probability distribution is used to model time between defects? A. Normal B. Poisson C. Binomial D. Chi square E. Exponential

25. A principle advantage of fractional factorial experimental designs is: a. Reduced cost. b. Improved accuracy. c. Increased confounding. d. Higher confidence level.

26. A principle disadvantage of fractional factorial experimental designs is: a. Improved accuracy. b. Confounding of effects. c. Higher confidence level. d. Reduced probability of type II errors.

Use the following information for questions 27-28.

27. Calculate the main effect of factor A. a. 20. b. 25. c. 30. d. 45.

28. Calculate the interaction effect. a. 0. b. 10. c. 20. d. 30.

29.The process of a group spontaneously proposing solutions to a problem is an example of: A) Motivating. B) Forming. C) Benchmarking. D) Brainstorming.

30. Which of the following terms associated with experimental design is used to develop products with reduced sensitivity to uncontrollable sources of variation? A) Robust. B) Optimal. C) Completely randomized. D) Variance decomposition.

31. A hockey team's fan attendance for the season is plotted as a function of the number of wins in a season, and the correlation coefficient is determined to be -0.89. Which of the following statements best describes the data? A) There is weak negative causation between the number of wins and attendance. B) There is strong negative causation between the number of wins and attendance. C) There is weak positive correlation between the number of wins and attendance. D) There is strong negative correlation between the number of wins and attendance.

32. Six Sigma methods are usually considered to be more effective than lean methods for solving problems that require: A. Extensive data analysis B. Optimizing an assembly line C. Coordination with suppliers D. A quick solution

33. During the norming stage of team development: A. Team members begin working together B. Team members tend to express their own opinions C. Team members present a final report and fight to support it D. All of the above E. None of the above

34. The project management tool for listing all individual activities that must be accomplished in order to complete the project is called: A. Gantt chart B. Tollgate review C. Work breakdown structure (WBS) D. RACI model (responsible, accountable, consulted, informed)

35. If a gage doesn't get the same answer each time it is used to measure the same item, the measurement systems lacks ___________ A. homogeneity B. bias C. accuracy D. precision

36. When a random sample from a normal population is plotted on normal probability graph paper, the resulting shape is typically: A. approximately linear B. skewed to the left C. symmetric D. bell shaped

37. A difference between descriptive and inferential statistics is that: A. descriptive statistics is always verbal. B. inferential statistics is based on the central limit theorem. C. inferential statistics reaches a conclusion about a population based on analysis of a sample. D. descriptive statistics produces graphical results.

38. When a Six Sigma team, confronted with a processing problem, applies the 5 Whys technique, they are attempting to: A. Eliminate areas not to investigate B. Understand the basics of the problem C. Determine the root cause of the problem D. Determine if the interviewee is telling the truth

39. A process control chart is primarily used to: A. Measure process capability B. Determine causes of process variation C. Detect non-random variation in processes D. Determine if defective parts are being produced

40. The Pugh analysis design technique can be summarized as: A. A hybrid two-step design methodology. B. An iterative process to arrive at a winning design. C. An expansion of a baseline design using multi-voting. D. A technique in which a team gathers technical knowledge.