Six Sigma Green Belt

Juran

The Root Cause Corrective Activation method should be used…

to address sporadic problems

Dr. Juran said that "All improvements happen ________?_________ and in no other way

project by project

What continuous improvement method should you use to improve an existing process?

Six Sigma DMAIC (Define Measure Analyze Improve Control)

Project method: Plan should use

Six Sigma DMADV (Define Measure Analyze Design Verify)

Project method: Control should use

Six Sigma DMAC (Design Measure Analyze Control)

Project method: Improve should use

Six Sigma DMAIC (Define Measure Analyze Improve Control)

A process is

a value stream

A value stream includes

all activities which are required to bring goods or services from conception to commercialization

The father of the Toyota Production System and the Seven Types of Waste was ______________.

Taiichi Ohno

? = f(x) when talking about improving a process?

The project Y

In terms of process efficiency, government regulations are what type of waste?

Non-value added, but necessary

If a process is running perfectly (at a 6σ level) and can product 1,000,000 products, how many errors can be expected?

3.4

What actions are an important role for the Continuous Improvement Council?

Review progress, and assist teams in the event of obstacles

People in what role develop, coach, and lead multi-functional improvement teams?

Black Belt

Who provides leadership to management groups in the integration of Continuous Improvement approaches within an organizations business strategy?

A master black belt

1st stage of team growth

Forming

2nd stage of team growth

Storming

3rd stage of team growth

Norming

4th stage of team growth

Performing

2 characteristics of effective teams

Consensus decisions, Clear purpose

Questions that help team members respond effectively are _________ questions

Clarifying and Confirming

Which method is used to reduce variation?

DMAIC

When multiple teams try to improve the same problem, they often

come up with the same solution

Lean is used to

reduce delivery time

which DMAIC tool is used to focus on the project Y?

Pareto analysis

You quantify the problem statement in which step of the DMAIC methodology?

Define

An example of a Lean tool

6S

Lean processes known as "cells" or "lines" are usually situated in what shape?

horseshoe

Lean can be…

combined with other methodologies

All improvement opportunities fall into the following categories

Faster, Better, Cheaper

The Cost of Poor Quality consists of…

all costs that would disappear if everything worked perfectly

The finance department is…

involved in the project reporting cycle

This is included in a project charter

project scope

The first step to selecting projects is to

Identify potential projects

MOMS acronym

Measurable, Observable, Manageable, Significant

COAQ

Cost of Attaining Quality

TCOQ

Total Cost of Quality

COPQ

Cost of Poor Quality

COAQ + COPQ =

TCOQ

Cost of Poor Quality =

Actual Cost - Minimum Cost

Most costs associated with COPQ are

Hidden

What is DMAIC?

a five step methodology that organizations use to achieve breakthrough improvement

in Y = f(x) the Y is…

the defect

in Y = f(x) the f(x) is…

unknown causes to be discovered by the improvement team

the voice of the customer should be recorded…

verbatim

A Pareto diagram helps improvement teams determine…

the "Vital Few" factors leading to an effect

Why should a project team conduct a stakeholder analysis?

To help develop strategies that influence stakeholders

What is the first step a team should take when collecting the voice of the customer?

Record the issue in the customer's own voice

What tool should a project team use when identifying and grouping key issues?

Affinity Process

How many process steps are included in a SIPOC diagram?

4-8

What is the order to fill out a SIPOC diagram?

Process > Output > Customer > Input > Supplier

When writing process statements for a SIPOC, use…

verbs

What column in a SIPOC diagram gets filled out after the process step?

Output

What should be used to describe process outputs in a SIPOC?

Nouns

The two types of measures are on _____ and _____.

efficiency, effectiveness

the 80/20 rule

80% of failures are caused by 20% of the defects

the Pareto Principle

any group of factors contributing to a common effect, a relative few of the contributors account for most of the effect

the Vital Few

A small number of sources account for most of the problem

the Useful Many

The large number of remaining sources individually and collectively account for a relatively small part of the entire problem

When there is not a clear breakpoint between the vital few and useful many, the area in between is called the…

Awkward zone

The first step in developing a data collection plan is to…

Make a list of questions to be answered

The tool used to collect data is called…

the sensor

sample size = [ (confidence/variation) / ____________ ]^2

precision

________ is the presence or influence of any factor that causes the population or process being sampled to appear different from what it actually is

Bias

How do you validate a process map?

walk the process

on a process map, an activity symbol is depicted as…

a rectangle

Lean tool 6S, S1:

Sort

Lean tool 6S, S2:

Set in Order

Lean tool 6S, S3:

Sweep and Shine

Lean tool 6S, S4:

Standardize

Lean tool 6S, S5:

Self-Discipline

Lean tool 6S, S6:

Safety

What are Red Tags used for?

Showing disposition for an item (S1: Sort)

What does a Value Stream Map include?

All process steps required to complete a service or produce an output

The sequential order of activities needed to deliver work units to a customer in order to complete a process is known as…

Flow

Demand =

[Product or Service] / Time

Capacity =

[Work effort or Available time] / Longest Cycle Time

__________ is the amount of time it takes for a customer to order one unit of demand

Takt Time

What is lead time?

the overall time from order to delivery

Why should you analyze data?

To determine which theories are the root cause of the problem

What tool should be used to narrow down the list of theories created by the team?

Pareto Analysis

What kind of chart is good for showing proportions?

Pie chart

What kind of graph or chart is useful only when the sum of dependent variables are meaningful?

Stacked bar graph

What tool quickly displays stratified data?

Pareto diagram

If initial stratification does not yield useful results…

stratify by other variables

a normal "perfect" distribution is called

a bell shaped distribution

there are three important characteristics to histograms; its center, its width, and ________

Its shape

How many data points do you need to create a reliable box plot?

8

What do you need to do with your data before you create a box plot?

Put the data points in order

How many data points should you have in order to create a scatter diagram?

at least 40

What is the first step of 5-Why Analysis?

Write down the specific problem statement

RPN stands for

risk priority number

How to calculate RPN

Severity * Occurrence * Detection

What tool is the bases for causes listed on an Impact Control Matrix?

Cause-Effect diagram

Barriers and Aids charts are visual models of _________ often unseen or overlooked when incurring change

challenges

What tool do you use to come up with lists of barriers and aids?

Brainstorming

What is the purpose of a Barriers and Aids chart?

To display potential barriers and identify ways to overcome them

A Pugh matrix compares concepts against a ________

baseline

control charts show

variation in a process

Errors are causes of

defects