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IASSC Lean Six Sigma – Black Belt

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Question # 1

An operator is measuring the distance between two points. Which is most likely to be influenced by the operator?

Options:

A.  

Precision of the measurement

B.  

Accuracy of the measurement

C.  

Calibration of the instrument

D.  

All of these answers are correct

Discussion 0
Question # 2

If a Six Sigma project was to reduce repair station inventory and the team found the inventory was creeping up over time which Lean tools should be considered in the Control Phase to reestablish and sustain the project success?

Options:

A.  

Review the Visual Factory to assure inventory in excess of desired visible

B.  

Improve the lighting to assure adequate visibility

C.  

Analyze data from supplier deliveries

D.  

Reword the standardized work instructions to use active verbs and not passive phrases

Discussion 0
Question # 3

If in an experiment all possible variable pairs sum to zero the design is Orthogonal.

Options:

A.  

True

B.  

False

Discussion 0
Question # 4

Use this data to calculate the Z score. Average o

F.  

65, Standard Deviation: 3, Upper Spec Limit: 72

Options:

A.  

0.27

B.  

1.5

C.  

2.33

D.  

4.12

Discussion 0
Question # 5

Which of these elements are not included in Implementation plans?

Options:

A.  

Work breakdown structure

B.  

Cost/Benefit ratios

C.  

Risk management plans

D.  

Planned audits of work completion

Discussion 0
Question # 6

Much of the Six Sigma methodology is used to identify and remove causes for _____________ .

Options:

A.  

Process Variation

B.  

Material Costs

C.  

Excess Inventory

D.  

Lost Sales

Discussion 0
Question # 7

For a Normal Distribution as samples size increases the Range in Mean and Standard Deviation decrease relative to the Mean and Standard Deviation of the population.

Options:

A.  

True

B.  

False

Discussion 0
Question # 8

Which of the items listed do not define what an X-Y Diagram is?

Options:

A.  

Created for every project

B.  

Based on team's collective opinions

C.  

Updated whenever a parameter is changed

D.  

Used to show each step in a process

E.  

A living document throughout project lifecycle

Discussion 0
Question # 9

With Measurement System Analysis we are concerned with two issues that impact the potential variability of the data. They are ____________ and Accuracy.

Options:

A.  

Spread

B.  

Reliability

C.  

Precision

D.  

Deflection

Discussion 0
Question # 10

The two types of data that can be used in Statistical Analysis are Attribute and Variable.

Options:

A.  

True

B.  

False

Discussion 0
Question # 11

In a good Measurement System the most variation will be with part-to-part measurements. What should you do if the majority of variation is associated with the Gage R&R assuming the gage is technically capable?

Options:

A.  

Focus on fixing the Repeatability and Reproducibility of the measurement device

B.  

Purchase a new machine

C.  

Focus on trimming the Part-to-Part variation

D.  

Run another MSA test with the machine

Discussion 0
Question # 12

Sally and Sara sell flower pots at their garage sale. Martha motivates Rose mentioning that they will sell a minimum of 16 pots per day if the outside temperature exceeds 60o

F.  

From a sample, whose population is assumed to follow a Normal Distribution, taken for 30 days at 60 degrees or more an average of 15.2 pots per day were sold with a Standard Deviation of 0.6 pots. What is the Z value for this sales process?

Options:

A.  

0.67

B.  

1.13

C.  

1.33

D.  

2.66

Discussion 0
Question # 13

A Belt working in a supply chain environment has to make a decision to change suppliers of critical raw materials for a new product upgrade. The purchasing manager is depending on the Belt’s effort requiring that the average cost of an internal critical raw material component be less than or equal to $3,800 in order to stay within budget. Using a sample of 38 first article components, a Mean of the new product upgrade price of $3,680, and a Standard Deviation of $120 was estimated. In order to increase the Long Term Z value to 5, what is the maximum long term variation in pricing the Belt can accept for his upgraded critical raw material component?

Options:

A.  

$6

B.  

$12

C.  

$24

D.  

$48

Discussion 0
Question # 14

On a _________________ a Belt screens variables, or various inputs, to analyze their relative impact on the output of concern.

Options:

A.  

X-Y Matrix

B.  

Weighted Scale

C.  

Multi-Vari Chart

D.  

Poisson Chart

Discussion 0
Question # 15

One of the foundations of Lean Six Sigma is the concept that the output of a process (Y) is influenced by the process inputs (X’s) and is commonly shown as which formula?

Options:

A.  

Y = Z(X2)

B.  

Y = f(X3)

C.  

Y = f(Xn)

D.  

Y = g(X+ 1.5)

Discussion 0
Question # 16

For a Kanban to be successful which of these must occur?

Options:

A.  

Consistent cycle times

B.  

Fairly stable process demand of product or service

C.  

Low defect rate of incoming product or service

D.  

All of the above

Discussion 0
Question # 17

What is the Ppk of a process with a spread of 24 units, an average of 68, an upper limit of 82 and a lower limit of 54?

Options:

A.  

1.68

B.  

2.00

C.  

4.00

D.  

4.42

Discussion 0
Question # 18

Which of these items are not part of what is necessary for successful Kaizens?

Options:

A.  

Good lighting

B.  

Management support

C.  

Operator support

D.  

Analysis tools

Discussion 0
Question # 19

Accuracy can be assessed in several ways and a fairly accurate means of measurement is visual comparison.

Options:

A.  

True

B.  

False

Discussion 0
Question # 20

The English words used for the 5S’s are Sorting, Straightening, _____________ , __________ and Sustaining. (Note: There are 2 correct answers).

Options:

A.  

Shaping

B.  

Shining

C.  

Standardizing

D.  

Signing

Discussion 0
Question # 21

How many experimental runs exist in a Full Factorial and fully randomized design for 4 factors with 2 replicates for the Corner Points and no Center Points? The factors in the experiment are only at 2-levels.

Options:

A.  

10

B.  

32

C.  

256

D.  

64

Discussion 0
Question # 22

In a Fishbone Diagram the 6M’s stand for Methods, ____________, Machine, Man, Mother Nature and Materials.

Options:

A.  

Measurements

B.  

Merger

C.  

Management

D.  

Medical

Discussion 0
Question # 23

Some of the sources for different types of error that can be quantified using Statistical Analysis are which of these?

Options:

A.  

Error in sampling

B.  

Bias in sampling

C.  

Error in measurement

D.  

All of the above

Discussion 0
Question # 24

The Greek letter “sigma” is used by mathematicians to signify _____________.

Options:

A.  

Curve Width

B.  

Numerical Average

C.  

Standard Deviation

D.  

Data Spread

Discussion 0
Question # 25

Screening experiments are the proper choice when a Belt is faced with the situation of highly Fractional Factorial Designs.

Options:

A.  

True

B.  

False

Discussion 0
Question # 26

Which of these elements are not included in Implementation plans?

Options:

A.  

Work breakdown structure

B.  

Risk management plans

C.  

Cost/Benefit ratios

D.  

Planned audits of work completion

Discussion 0
Question # 27

Assessing process proportion as opposed to evaluating a process with respect to a set target can be done using which of these?

Options:

A.  

Process proportion equals some value range

B.  

Process proportion equals some desired value

C.  

Target is current

D.  

Proportion of the tail is equal

Discussion 0
Question # 28

Assessing process proportion as opposed to evaluating a process with respect to a set target can be done using one or more of these. (Note: There are 2 correct answers).

Options:

A.  

Process proportion equals some desired value

B.  

Process proportion equals some value range

C.  

Target is current

D.  

When we deal with Attribute type data

E.  

Proportion of the tail is equal

Discussion 0
Question # 29

Fractional Factorial designs are used to reduce the ____________ because the number of runs has been lowered.

Options:

A.  

Time and cost of experiments

B.  

Number of people involved

C.  

Number of data measurement points

D.  

Output summary

Discussion 0
Question # 30

Calculate the Rolled Throughput Yield of this process using this data.

Dat

A.  

unit input: 1450, unit output: 1390, defects repaire

D.  

320, scrap: 60

Options:

A.  

71.33%

B.  

72.66%

C.  

73.79%

D.  

77.93%

Discussion 0
Question # 31

Following the completion of a LSS project the Belt not only creates a Control Plan he also develops a _____________ so those involved in the process know what to do when the critical metrics move out of spec.

Options:

A.  

Response Plan

B.  

Call List

C.  

Chain-of-Command

D.  

Defect Analysis Plan

Discussion 0
Question # 32

Following process modifications, the Null Hypothesis states that no improvement to the process has occurred. If we discover the Null Hypothesis Test was rejected when it was false that would be a(n) _______________.

Options:

A.  

Type I Error

B.  

Type II Error

C.  

Type III Error

D.  

Alpha Error

Discussion 0
Question # 33

Statistical Difference is the magnitude of difference or change required to distinguish between a true difference, brought about by change or improvement, and one that could have occurred by chance.

Options:

A.  

True

B.  

False

Discussion 0
Question # 34

A valuable tool to use during the Measure Phase to show material and information flow throughout an entire process is the ______________ .

Options:

A.  

Value Stream Map

B.  

FMEA

C.  

Pareto Chart

D.  

Standard Operating Procedure

Discussion 0
Question # 35

When variation is removed from the output of a process then the process customer can have more confidence in the experience that results from the process.

Options:

A.  

True

B.  

False

Discussion 0
Question # 36

How many experimental runs exist in a Full Factorial and fully randomized design for 5 factors with 2 replicates for the Corner Points and no Center Points? The factors in the experiment are only at 2-levels.

Options:

A.  

10

B.  

128

C.  

256

D.  

64

Discussion 0
Question # 37

The calculation of Column Total times Row Total divided by Grand Total yields expected values from what type of chart?

Options:

A.  

Pareto Chart

B.  

Sakami Table

C.  

Contingency Table

D.  

None

Discussion 0
Question # 38

The Lean toolbox includes all of the following items except __________.

Options:

A.  

Poke-Yoke

B.  

Standard Operating Procedures

C.  

Kaizen

D.  

5S the work area

Discussion 0
Question # 39

Which statement(s) are correct about the Factorial Plot shown here? (Note: There are 3 correct answers).

Question # 39

Options:

A.  

When the cutting speed increased from low to high level, the tool age increases

B.  

The coefficient of the metal hardness is positively related to the output of tool age

C.  

The coded coefficient is lower for cutting speed than the cutting angle related to the output of tool age

D.  

These plots prove a statistically significance factor with 95% confidence

E.  

These plots are an example of interaction plots

Discussion 0
Question # 40

To be an effective Lean Six Sigma practitioner one must understand the difference between ___________________________.

Options:

A.  

ANOVA and the Analysis of Variance

B.  

Nonparametric tests and tests of Non-normal Data

C.  

Practical and Statistical significance

D.  

F-test and test of variances of 2 samples

Discussion 0
Question # 41

Time is always the metric on the horizontal scale of a(n) ___________ Chart.

Options:

A.  

Pareto

B.  

Xbar

C.  

Multi-Vari

D.  

NP

Discussion 0
Question # 42

Range Charts are the technique used to determine if ______________ are occurring within the subgroups of the SPC Charts.

Options:

A.  

Common Causes

B.  

Special inspections

C.  

Unnatural forces

D.  

Special Causes

Discussion 0
Question # 43

Which statement(s) are incorrect about Fractional Factorial Designs?

Options:

A.  

A Half Fractional Design for 5 factors has the same number of experimental runs as a Full Factorial Design for 4 factors assuming no repeats or replicates or Center Points

B.  

Quarter Fractional experiments can exist for those with 4 factors

C.  

Resolution V design is desired while controlling costs of experimentation

D.  

Half Fractional experiments do not exist for those designs with only 2 factors

Discussion 0
Question # 44

Screening experiments are the proper choice when a Belt is faced with the situation of highly Fractional Factorial Designs.

Options:

A.  

True

B.  

False

Discussion 0
Question # 45

A Non-parametric Test should be used if just one distribution is not Normal out of the two or more gathered.

Options:

A.  

True

B.  

False

Discussion 0
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