Six Sigma Practices Questions 4 -- (ASQ) Test

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1.

A1C is a measure of sugar in the blood. The Mayo Clinic says a healthy person should have an
A1C reading between 4.5% and 6.0%. Someone who already has diabetes will typically have an
A1C level of 8%. A common treatment goal for people with diagnosed diabetes is an A1C of less
than 7%. A pharmaceutical company is working on a new diabetes drug to reduce A1C and is
ready to do atrial comparing the drug to a placebo. What significant difference in A1C should
the company look for?
1.0%
0.6%

because 1.5% is enough to make

a practical difference for the
patient with diabetes and will
require fewest samples.
A 1.0% difference would help
many patients however the
sample size would be more than
twice as big as when testing for a
difference of 1.5%, driving up the
cost of the experiment.

1.5%
0.6%
2.

After obtaining the mean for all x-values and the mean for all y-values when calculating
correlation coefficient, what is the next step?
Sum all the values and divide the sum by Sx x Sy

Calculating the standard

deviation for all x-values and the
standard deviation for all yvalues is the correct 2nd step

Calculate the standard deviation for all x-values and the standard deviation for all y-values
Calculate x- x-bar, and y- y-bar for each pair (x.y) and then multiply those values together
Sum all the values and divide the sum by Sy x Sx
3.

An agriculture company is presented with two different methods for testing heavy metals in
fresh produce. In order for this company to determine which method is more precise, it runs
several tests using both methods and receives comparable results. The company decides to
run an F-test to determine which method is more precise. What type of F-test should be used?

We use a one-tailed test in this

case because the only
information we are interested in
is whether Method 1 is more
precise than Method 2.

Double-ended test
One or two tail test will give the same result.
One-tailed test
Two-tailed test
4.

An agriculture company is presented with two different methods for testing heavy metals in
fresh produce. In order for this company to determine which method is more precise, it runs
several tests using both methods and receives comparable results. The company decides to
run an F-test to determine which method is more precise. Which of the following can be used
as the alternate hypothesis for such test? (Note: = standard deviation)

Correct!
HA: 22(Method 2) > 2 (Method
1) is a correct alternate
hypothesis for testing which
method is more precise than the
other

HA: 2 (Method 2) = 2 (Method 1)

HA: 2 (Method 1) 2 (Method 2)
HA: 2 (Method 2) > 2 (Method 1)
H0: 2 (Method 1) > 2 (Method 2)

HA: 2 (Method 2) = 2 (Method

1) statement describes what the
null hypothesis should be for a
two tailed test

5.

All of the points fall within the control limits and no unusual patterns are
present. The control limits define the extent of:
Special-cause variation

Correct!W. Edwards Deming called the variation

inherent in the process as common-cause
variation because it is common to the whole
process.

Assignable-cause variation
Common-cause variation

Walter A. Shewhart referred to points out of the

control limits or unusual patterns as being due
to assignable-cause variation.

Engineering tolerances
6.

All of the sample sizes are equal. Which of the following charts is the most
appropriate to substitute for a p chart?
I chart

Correct!
The np chart is appropriate when the statistic in
question is the number of nonconforming items
out of the total number of items inspected and
the subgroup size is constant.

np chart
c chart
u chart

7.

The c chart is appropriate only when the

statistic of interest is the number of occurrences
of an attribute for a given area of opportunity,
where the area of opportunity remains
constant for all subgroups.

The Billing department of a firm has been keeping an np chart on defective

invoices. They sample 50 invoices a week and over the past year their average
number of defective invoices has been 4.1. In order to save time, they are going
to reduce the sample size to 40. What are the new control limits for the np chart
with sample size of 40?

Correct! Control limits for the np charts = 0 and

9.854
Using the formula from page 323 of the CSSGB
Handbook, with np bar = 4.1, n = 40

0 and 7.936

Upper control Limit=

2.182 and 6.018

np-bar + { 3 [square root of product of np-bar

( 1- (np bar/n)]}

0 and 9.854
4.1 + { 3 [square root of [4.1 (1 - (4.1/ 40))]}
0 and 9.920
4.1 + 3 [square root of [4.1 (1 - (0.1025))]}
4.1 + 3 [square root of [4.1 (0.8975)]}
4.1 + 3* [square root of [3.67975)]}
4.1 + 3* [1.9182]= 4.1 + 5.75= 9.85
Lower Control Limit
np-bar - { 3 [square root of product of np ( 1(np bar/n)]} = 4 - (5.75) = - 1.75

8.

A chemical process is run at 3 different temperatures. Five trials at each temperature. The average
product yields are 89, 91 and 93%. Assuming you have the complete data set, which of the following
would be the best analysis to determine whether there is a statistically significant difference between
product yields?
Process capability

Correct! ANOVA
used to determine
whether the
differences among
population means
are statistically
different.

Analysis of variance
Run charts

Run charts may

show difference, but
not quantitatively.

Linear regression models

Process capability is
used to measure
process
repeatability e.g. to
meet specifications.
Linear regression
models show
relationship
between 2 variables.
9.

The chief operating officer wants to know if the 17th quarter's customer satisfaction survey result, 88, "is
a statistically significant improvement of the mean at the 95 % confidence level and why?" The following
facts apply: The data are collected by a proper survey method and are normally distributed and twotailed. The mean satisfaction result for the last 16 quarters is 85.8. The standard deviation of the
population is 3.06. The standard error calculated by the data analysis software is 0.79 (n=15) (two-tailed tstatistic is 2.13).

Correct!
The standard error
of the population
data will be smaller
than the standard
error treating the
data as a sample

No, the mean is within the 95% confidence interval.

Yes. The upper limit of the 95% confidence interval for the mean is less than 88 when corrected for the use
of a population instead of a sample.
Unable to form a conclusion. To determine a statistically valid answer, at least 30 quarters of data are
required.
No. The lower limit of the 95% confidence interval for the mean is greater than 88.
10.

Choose the most appropriate statement that applies to the term kaizen.
A three- to five-day event.
A way to provide quicker implementation of results.
A way to obtain breakthrough improvement.
Small continuous improvements.

Correct!
Kaizen is a
philosophy of small,
gradual continuous
improvements.

11.

A company conducted an on-site supplier workshop. In one exercise the

suppliers were instructed to walk through the factory and write down examples
of locations of excess inventory, unnecessary movement of material, and
unneeded employee movements. The information gathered is an example of
which of the following?

Correct!---Muda translates to "waste" and has

several categories. In this case, waste of
material, waste of transportation, and wasted
motion.

Kaizen blitz
Defects

A kaizen blitz is an offshoot of kaizen, in which

an intense focus is on one activity and
implements significant improvements

Audit findings

Remaining choices are not relevant

Muda
12.

A company is testing a new material it developed and has designed an

experiment to determine how temperature and pressure impact the strength of
the material. Temperature and pressure have two levels (high and low), and the
experiment is set up to be repeated once. Which comparison will provide the
company with an estimate of the experimental error?
Difference measured between first and second runs of the same combinations
Difference measured between high pressure and low pressure results
Difference measured between high pressure and high temperature results

13.

Correct! Comparing first and second results

for the same combinations will provide an
estimate of error.

Comparing high and low pressure results will

estimate the effect of the pressure factor only.
High pressure compared to high temperature
will provide a partial estimate of the effect of
each factor.

Difference measured across all combinations

Comparing the difference across all

combinations will estimate the total variation.

A company that makes axles wants to reduce the variation in the diameter of its
axles. The long term standard deviation in diameter has been 1.98 mm. The data
is normal. A new process has been developed which produced a standard
deviation of 1.41mm on 12 samples What is the confidence that the company
should place on the conclusion that the new process will produce a lower
variation?

The Test Statistic X2=((121)*1.412)/(1.982)=5.578 From the Chi Squared

Table with dof =11, the 90 % value for 90%
confidence is 5.58. The test statistic is just less
than the Chi squared vale for 90%, so 90% is
the best answer

10%

94% would be true if the dof = 12 but dof = n-1

= 11

90%
94%
80%
14.

A control chart is being kept on the total number of scratches on five inspected
car hoods. The most appropriate control chart is:
p chart
np chart

Correct!
The c chart is appropriate when the statistic of
interest is the number of occurrences of an
attribute for a given area of opportunity,
where the area of opportunity remains
constant for all subgroups, which is the case
here on five hoods.

c chart
u chart

The u chart could be used here for the ratio of

the number of occurrences of a scratch to the
area of opportunity, one hood. But since the
subgroup size is constant (at size 5), a c chart is
more appropriate.

15.

control chart is to be kept on the temperature of a process

recorded each day at noon. Which of the following is the
most appropriate control chart to use?

Correct ! I-chart---The data points come one at a time (one per day).
There is no need to wait to accumulate data for a subgroup.
remaining are attribute charts and cannot plot temperature

u chart
p chart
c chart
I chart
16.

A control chart is used to control a paper towel line. The

end product is produced in rolls of varying length 12
inches wide. Nonconformities include tears, improper
printing, improper perforations, etc. The control statistic
is defects per 100 sheets with one roll constituting a
sample. Which control chart is most appropriate to use?

Correct! The u chart is appropriate when the statistic of interest is the

ratio of the number of occurrences of an attribute to the area of
opportunity. In this case, it is the number of nonconformities divided
by the length of the roll in hundreds of sheets. Here, the area of
opportunity (subgroup size) varies because one roll constitutes a
sample and the rolls are of varying length.

c
p
np
u

The c chart is appropriate only when the statistic of interest is the

number of occurrences of an attribute in a given area of opportunity,
where the area of opportunity remains constant for all subgroups. In
this case the number of nonconformities is divided by the length of the
roll in hundreds of sheets. Thus, the subgroup size varies because one
roll constitutes a sample and the rolls are of varying length.
The p chart is appropriate only when the statistic in question is the
proportion of nonconforming items out of the total number of items
inspected.
The np chart is appropriate only when the statistic in question is the
number of nonconforming items out of the total number of items
inspected and the subgroup size is constant.

17.

A control plan is best defined as:

The natural boundaries of a process within specified
confidence levels, expressed as the upper control limit
and the lower control limit.
A written description of the method for controlling part
and process quality by addressing key characteristics and
engineering requirements.
A solution meant to reduce or eliminate an identified
problem.
A document specifically details the level of compensation
that each stakeholder should receive after the process has
been improved.

Correct! A control plan provides a documented description of the

direct relationship between any highlighted characteristics and their
controlling process setting or parameter.
While upper and lower control limits may be featured in a control plan,
this statement best describes control limits.

18.

The current process has a mean of 2.50 and a std

deviation of 0.05. A new process has been suggested by
research. What sample size is required to detect a
process average shift of 0.02 at the 95% confidence level?

Correct!
The correct formula is N = (0.05 (1.96)/0.02)2 = 24.01, round up to 25 0.05
= sigma 0.02 = amount of change you wish to detect 1.96 = z value from
table at 95%, remember to use two tail

16
5
Insufficient information to determine sample size
25
19.

Data has been collected every day for the last 3 months
from all three shifts. How should the data be organized
if it is to be analyzed using an Xbar and s control chart to
compare the shifts?

Correct!
Rational Sub Grouping will allow you to compare both sample to sample
process shifts and establish within sample variation. Since all product
made on a shift is assumed to be similar we can compare the Xbar S
charts for each shift for common and special causes of variation.

Create an Analysis of variance table to calculate the shift

to shift contribution to variation
Create a matrix of the Process Capability by shift of key
quality characteristics

Analysis of variance is not a control chart but a statistical technique with a

similar objective to an Xbar and s control chart.

Organize the data by type of defect and compare

frequency of defects from shift to shift

Process capability is concerned with process performance. Although it

may be useful it was not what the question asked which was to
comparing the shifts with an Xbar and s control chart.

Organize the data using rational subgroups from each

shift
20.

The degrees of freedom for a contingency table

containing 3 rows and 4 columns is:
7
12
11
6

Pareto analysis uses a Pareto chart (a "bar chart" arranged in decreasing

order of frequency or amount) which is not an Xbar and s control chart.
Df=(r-1)(c-1)=2 * 3 = 6

21.

Devise a sampling plan for obtaining a

representative moisture sample from an open top
railcar of coal, where the contents are known to
have changed and also stratified due to vibration
and exposure during the 10 days of shipment.
A) Draw a slipstream sample by taking a
representative slice of the bulk material as the car is
being unloaded being certain to capture all of the
generated dust.

Drawing a slipstream sample by taking a representative slice of the bulk

material as the car is being unloaded being certain to capture all of the
generated dust samples the entire railcar following arrival and allows
assessment of moisture and changes in material from initial shipment.
The product will have changed during transit in terms of moisture content or
in other properties such as changes from particles blown off the car during
shipment. Therefore, the analyses of the initial product will not represent the
received product, regardless how careful and accurately the analyses are
done by the supplier.

B) Draw a quota sample with one sample off the top

and from five more standardized depths in the
railcar.

Drawing a convenience sample from multiple points that can be easily

accessed is a non-probabilistic sample.

C) Receive a certificate of analysis from the supplier

of a sample properly collected from the entire load
at the time of loading knowing that the coal got
wet and dust blew off the open railcar.

Drawing a quota sample with one sample off the top and from five more
standardized depths in the railcar. is a non-probabilistic sample because the
sampler has no prior knowledge of the stratification, has no equally spaced
distribution plan, and likely has skewed the data by taking the sample from
the top, but apparently not from the very bottom.

D) Draw a convenience sample from multiple

points that can be easily accessed.
22.

The difference between the observed result and the

predicted value for that result based on the
empirically determined assumed model is called
which of the following?
Residual error
Precision error

Correct! Residual error or experimental error is the variation in the

experimental response under identical test conditions
Precision error is a measure of how well repeated measurements under
unchanged conditions show the same results, not differences compared to an
assumed model.
Relative error gives an indication of how good a measurement is relative to the
size of the item being measured.

Remainder error
Relative error
23.

During an experimental run, setting a single level to

a single factor is called?

Correct!
Setting a single level to a single factor is a treatment.

Bias

Balance is when all combinations have the same number of observations

Screening

Bias is systematic error.

Treatment

Screening is a lower resolution experiment used to reduce a large number of

possible factors down to the critical few.

Balance

24.

Each day, 100 items are inspected and the number of rejected items is
recorded. You are asked to make a control chart, where the statistic in
question is the number of nonconforming items out of the total number of
items produced, that takes advantage of the equal size subgroups. Which
control chart is most appropriate to use?

Correct! The np chart is appropriate when the

statistic in question is the number of
nonconforming items out of the total number of
items inspected and the subgroup size is constant
(here the subgroup size is 100).

c
u
np

The c chart is appropriate only when the statistic of

interest is the number of occurrences of an
attribute divided by the area of opportunity, where
the area of opportunity remains constant for all
subgroups.

p
The u chart is appropriate only when the statistic of
interest is the ratio of the number of occurrences of
an attribute to the area of opportunity.
The p chart is appropriate when the statistic in
question is the proportion of nonconforming items
out of the total number of items inspected.
25.

Each day the number of rejected bulbs out of a sample of 100 bulbs is
recorded as a subgroup. To take advantage of the equal subgroup sizes, the
most appropriate control chart is:
u
np
c

Correct! The np chart is the most appropriate chart

when the statistic in question is the number of
nonconforming items (rejected bulbs) out of the
total number of items inspected and the subgroup
size is constant (here set at 100).
The p chart could be used because the statistic in
question is the proportion of rejected bulbs out of
the total number of items inspected.

p
26.

Elements of a visual factory include which of the following?

Lines painted on the floor

Correct!
Lines painted on the floor can be used for
communicating such as indicating where it is safe to
walk.

A project charter
Failure Modes and Effects Analysis
Control plans
27.

The finished control plan should include which of the following?

Action instructions, characteristic, machine and inspectors name
Readings, process capability, subgroup size and control item
Graphical representation, supplier, special characteristics and test
equipment
A flow chart, gages, product name, sample size and specified reactions

Correct!
A control plan should include a flowchart or
graphical representation, gages or test equipment,
sample sizes and specified reactions or
troubleshooting solutions.

28.

A firm that manufactures stereo units has specifications set for the
clarity of sound produced by the finished unit. Each day between
100 and 200 units are inspected, and that sample size is recorded,
along with the number of rejected items. The proportion of rejected
items is calculated each day. Which control chart is most
appropriate to use?
u

Correct! The p chart is appropriate when the statistic in

question is the proportion of nonconforming items (rejected
items) out of the normal number of items inspected, which
here varies between 100 and 200.

The u chart is appropriate only when the statistic of interest

is the ratio of the number of occurrences of an attribute to
the area of opportunity.

c
p
np

The c chart is appropriate only when the statistic of interest

is the ratio of the number of occurrences of an attribute for
a given area of opportunity, where the area of opportunity
remains constant for all subgroups.
The np chart is appropriate only when the statistic in
question is the number of nonconforming items out of the
total number of items inspected and the subgroup size is
constant.

29.

The first five measurements taken in sequence from a process are:

10
14
12
13
21

Correct!
The moving range values are 4, 2, 1, 8. These average to
15/4 = 3.75.

What is the average moving range?

3
2.75
3.75
-2.75
30.

A fishing lure manufacturer precisely controls the weight of each

lure by adding lead to the lure before sealing it. The manufacturer
has decided to use SPC charts to understand and control its
manufacturing processes.
Which of the following charts would give them the best opportunity
to prevent making lures of the wrong weight?

Correct!
You want to choose characteristics that provide data for
diagnosing problems and test at the earliest point in the
production process where you can get information on
assignable causes to prevent non conformances. The
frequency assures sample to sample and within sample
variations can be measured.

An X bar R chart constructed using a sample of 5 lures pulled off the

manufacturing line every hour and measured for weight.

C& D = This is an attribute, which occurs long after the

product has been shipped so does not provide useful
information for controlling the process.
Close

An X Bar S chart based on weights of a box of 12 lures per shift

packaged and ready to ship.
The number of customer returns per 100 pieces shipped.
A P chart of non-conforming lures rejected each shift for weight out
of tolerance.

31.

For a control chart to be effective in detecting special-cause variation,

subgroups should be selected in a way that makes each subgroup as
homogeneous as possible and which gives the maximum opportunity for
variation to occur between subgroups. This is the key idea of:

Correct!
Walter A. Shewhart called it rational subgrouping
because it is rational to look at the data in such
ways.

Process capability
Rational subgroups
Common-cause variation

Common-cause variation is variation common to

the whole process and is always present.
Kaizen is continuing improvement and it is
unrelated to the subgrouping on control charts.

Kaizen
32.

For a range control chart with a sample size of 2, the lower control limit is
zero and the 3 upper control limit is 4.5. The last point plotted on the chart
was 5.2. This is an indication of what?
The process is in control.
The sample size should be changed.
The process variation has increased.

Correct! The process variation has increased.

An out of control signal on the range chart shows
the width of the process distribution has
shifted.The range of the process has changed more
than we would expect due to common causes.
You need at least 2 samples to get a range
measurement and increasing the sample size
would not decrease the range. It is time to
investigate the cause of the out of control point.

The process mean has shifted.

33.

For a time-ordered variables control chart, what is the primary reason why
subgroups should be kept as small as possible?
To save time.

Correct!To minimize the variation within the

subgroup.
The time-ordered variables control chart is most
effective if the variation occurs between subgroups
rather than within a subgroup.

To have the minimum opportunity for variation within a subgroup.

So ranges could be used instead of standard deviations.
So control limits may be narrower.

Ranges are used because they are easier to

calculate by hand, but the standard deviation is a
better measure of spread since it uses all of the
data.
When subgroups sizes are smaller, the control limits
are wider.

34.

A Green Belt determines that there are several potential sources of process
variation. If the engineer wishes to categorize related causes into families to
reveal the largest casual factors, the most appropriate tool to use is:
FMEA

ANSWER= MULTI-VAR!!

An FMEA is useful for identifying potential failures.

It does not identify potential sources of process
variation.

Binary Logistic Regression

Multi-Vari study
DOE

A Design of Experiment (DOE) is used for designing

and conducting experiments to determine
independent and response variables.

35.

A green belt has been asked to come up with a breakthrough improvement to

solve a process constraint. Which of the following process improvement tools or
methods should the green belt consider?
Kaizen

Answer= A kaizen blitz is used to obtain

breakthrough improvements.
Kaizen is a Japanese term for change for
improvement or improving processes though
small, incremental steps.

FMEA
Kaizen blitz

The purpose of FMEA is to understand the

opportunities for failure and the impact of
risks in a product or process design.

Interrelationship diagraph
Interrelationship digraphs are used to
identify cause-and-effect relationships.
36.

A Green Belt is calculating a confidence interval at a 95% level of confidence. She

should reject the null hypothesis if the calculated p-value is:

If you calculate a p-value at .05 at 95%

confidence, you should reject the null
hypothesis

Less than .05

Between .1 and .5

If the p-value is between .1 and .5, you should

not reject the null hypothesis at a 95%
confidence level

Between .5 - .95
Greater than .95
37.

A Green Belt is creating a regression model for estimation. He thinks that one has
to determine the closeness of the calculated z-scores to the actual coefficient
values for the population. The error in his thinking is that:

z-scores are not used in regression

models.The calculated values should be
closely aligned when compared to the
population

It is easy to calculate coefficient values

The coefficient values should be compared against the population

The coefficient values should be compared

against the population

The calculated values should be closely aligned when compared to the

population
He should calculate z-scores for the coefficient values
38.

A Green Belt noted that parts from a supplier had inconsistent metal hardness
from month to month shipments. He decided to conduct a multi-vari study. The
type of multi-vari study that he should run would be:
DOE
Positional
Temporal
Cyclical

Correct! A temporal study is to assess variance

over time

39.

A Green Belt noted that parts from a supplier had inconsistent metal thickness
from one location on the part to another. He decides to conduct a multi-vari
study. The type of multi-vari study that he should run would be:

Correct!
A positional study is to assess variance within a
single part.

Temporal
Positional
Cyclical
DOE
40.

A Green Belt wishes to determine the primary pattern (positional, cyclical or

temporal pattern) of variation in a process or product. Which of the following
techniques would be most useful?

A multi-vari design is used to identify variation

related to positional, cyclical and temporal
factors in the process/product.

Full Factorial

ANOVA does not break analysis down into

positional, cyclical and temporal contributions.

Multi-Vari
Analysis of Variance
Orthogonal Array
41.

A Green Belt wishes to identify sources of variation. She finds that there are
several sources of variation that need to be categorized. The most appropriate
tool for categorizing possible causes of variation would be a:

MULT-VAR!

DOE
Multi-Vari study
Binary Logistic Regression
FMEA
42.

A Green Belt wishes to sample castings due to some parts being out of
tolerance. Which of the following multi-vari sampling techniques would be
used for batch to batch sampling?
Positional

A positional study is to assess variance within a

single part.

DOE

A temporal study is to assess variance over time.

Cyclical

A Design of Experiment (DOE) is used for

designing and conducting experiments to
determine independent and response
variables.

Temporal
43.

A cyclical study is to assess variance from part to

part.

A hospital pharmacy has a large number of unfilled prescriptions. In lean

categories of waste this is considered which of the following?

Correct!--If people are unavailable to fill the

prescriptions and shipments are delayed, this is
an example of the lean category of waiting.

Kanban
Overproduction
Lost creativity
Waiting

Kanban is a system to replenish supplies, not a

lean waste.

44.

How can visual process controls improve and

control a workplace?

Correct! Visual process controls can be used to quickly identify abnormal

condition

By quickly identifying abnormal conditions.

SPC is used to statistically monitor a process.

By being a part of the control phase of a Six Sigma

project.

5S is used to keep a work area clan. 5S may be implemented as part of a visual

factory, but it is not a requirement for a visual work area.

By keeping the work area clean.

By statistically monitoring a process.
45.

How is a typical kaizen event structured?

The implementation of a visual workplace can be performed during the

control phase of a Six Sigma project; however, simply implementing a visual
workplace is not how a process is improved or controlled.
Correct!
These steps follow plan-do-check-act.

Observe the current condition, identify and

validate solutions, address the root causes of
problems found, and establish standard work.
Observe the current condition, address root causes
of problems found, identify and validate solutions,
and establish standard work.
Address root causes of problems found, observe the
current condition, identify and validate solutions,
and establish standard work.
Address root causes of problems found, establish
standard work, identify and validate solutions, and
observe the current condition.
46.

Identify two of the benefits of single-minute

exchange of dies (SMED).

Correct! SMED decreases the time to change dies, increases capacity and
throughput, and improves on-time deliveries to customers.

Decreased waiting time and increased quality.

SMED increases production, but it does not reduce the costs to purchase dies

Decreased changeover time and increased safety.

Waiting time may be decreased due to SMED; however, it is not implemented

for quality.

Decreased costs for purchasing dies and increased

production.

Although changeover times are decreased, safety is not the driving force in
implementing SMED.

Decreased inventory and increased capacity.

47.

If a company produces 100 compressors and 5

compressors have 2 defects each, what is the defects
/ unit (DPU) produced?
asq/learn_check.gif
0.10
5
95
0.01

(5 compressors * 2 defect each) / 100 produced = 0.10

Defects per unit is determined by total number of defects divided by the total
number of products produced in some time period.

48.

If all of the sample sizes are equal, which one of

the following charts is the most appropriate to
substitute for a u chart?

Correct! The c chart is appropriate when the statistic of interest is the number
of occurrences of an attribute for a given area of opportunity, where the area
of opportunity remains constant for all subgroups.

c chart
p chart

he np chart is appropriate only when the statistic in question is the number of

nonconforming items out of the total number of items inspected and the
subgroup size is constant.

I chart
np chart

An I chart is designed for individual measurements from a process in time (or

space) order.
An I chart is designed for individual measurements from a process in time (or
space) order.

49.

If a team is looking at ways to eliminate, combine,

simplify, or change steps in a process, what type of
analysis are they performing?
Cost of poor quality analysis
Critical-to-quality analysis
Cycle time analysis

50.

Correct!The four basic principles of cycle time analysis are: eliminate, combine,
simplify, and change.
mportance performance analysis studies customers' perceptions about both
the importance and the performance of products or services.
Critical-to-quality (CTQ) analysis is a way of studying the flowchart of a process
to identify quality features or characteristics most important to the customer
and to find problems

Importance performance analysis

Cost-of-poor-quality analysis is a way of studying a process's flowchart to

identify potential problems

The implementation of a pull system is being

considered. Which of the following is a
requirement for a pull system?

Correct!
A pull system should be used when there is consistent demand for the item.

There is consistent demand for the item.

Pull systems should be used when shortages have a significant impact on

service levels.

The part is always in stock when needed.

Pull systems should not be used when there is high variability in demand.

Demand for the item varies greatly.

The item is rarely needed.
51.

In addition to visually showing how much time is

spent at each step, what additional data may be
used on a cycle time chart?

Correct!
Costs and value/non-value added steps are two examples of what can be
useful for a team to visualize while analyzing a cycle time chart.

RPN

Costs and value/non-value added steps can be useful and would not be
restricted from a cycle time chart.

Costs and value/non-value added steps

Names of each operator
Only time; no other data can be used

52.

In Analysis of Variance, the F-statistic is a ratio that compares:

The variation within treatments to variation caused between the treatments.

Correct!
The F statistic is the ratio of variation caused by
the treatment to variation caused by
experimental error.

The variation within treatments to total sum of squares.

The variation between treatments to variation within treatments.
The variation caused by treatments to total sum of squares
53.

In an analysis of DOE results, which of the following graphic techniques would

best show the dependency effects of a range of input variables against the
response variable?

Correct! Interaction plots show interaction effects

of a range of input variables against the
response variable.

Histogram
A run-sequence plot would show trends in data.
Run-sequence plot of residuals
Interaction plot

Scatter plots show relationships between two

variables; DOEs often have many more than two
variables.

Scatter plot of residuals

Histograms show frequency distribution and
would be best used to identify if there were
outliers and shifts in response variation.
54.

In an experimental design, there are 8 machines that are run by 4 operators

where the switching mechanism with 2 positions will be observed. Identify
the maximum number of factors in this experiment.

Correct!
There are three factors: machine, operator, and
switching mechanism.

3
4
8
2
55.

In contingency tables, the null hypothesis is that the probabilities for each
outcome are independent is based on using which of the following
measurements?

Correct! Proportions
Attribute data, probabilities are determined
using Chi-square.

Standard Deviations
Variances
Means
Proportions
56.

In hypothesis testing, the Null hypothesis is:

Accepted when the test statistic falls within the rejection region
An assumption that is claimed to be true.
Influencing the level of significance for the test.
Used to calculate the test statistic

Correct!
Correct definition of null hypothesis--assumption
that is claimed to be true

57.

In the hypothesis testing of a normal distribution, what type of parametric test would be
used when comparing one sample average to a historical average or target?
z-statistic

Correct!
A t-test is the correct test to use
for comparing one sample
average to a historical one in a
normal distribution.

t-test
Weibull Distribution
Chi Square

Weibull Distribution is for

reliability.
The z-statistic is used for area
under the curve.
Chi Square is not for normal
distributions.

58.

A kanban is which of the following?

Used for determining effecting combinations of operations

Correct!---Kanban is a signal for a

particular action such as "move
material" or "produce a part."

Method for mistake proofing

Signal for a particular action

Standard work is used to

determine the most efficient
combinations of operations.

Used for low-cost gradual improvements

Poka-yoke is a method for
mistake proofing
Kaizen is used for low-cost
gradual improvements.
59.

A lab supervisor determined that performing 5 quality control tests on Product A instead of 6
lowers the confidence level that the batch is acceptable by a very small percentage. The
elimination of the 6th QC test saves 20 minutes per lot release. What advice would you give to
the lab supervisor?
Statistical significance is more important than economic factors. Leave the sixth test in
place.

Practical significance outweighs

the small change in confidence
level.
Statistical significance must be
balanced with economic and
engineering considerations.

The economic factors outweigh the statistical significance. Eliminate the sixth test.
More data is required. Leave the sixth test in place.
6 QC tests are the minimum required for lot release.
60.

The least squares regression equation relating appraisal cost growth to year of production is:
Appraisal Cost Growth Rate = 5.67 - (0.75) year. The model was constructed with 5 years of
data. Predict the appraisal cost growth rate in year 3.
1.92
4.92
3.42
4.17

5.67 - 0.75(3) = 3.42

61.

A long coil of coated wire is being inspected. The number of

defects or breakdowns in successive lengths of 1,000 feet each
is being recorded. It is desirable to take advantage of the
equal (constant) size subgroups of 1,000 feet. Which control
chart is most appropriate to use?

Correct! The c chart is most appropriate when the statistic of

interest is the number of occurrences of an attribute for a given
area of opportunity, where the area of opportunity remains
constant for all subgroups. In this case it is the number of
nonconformities (breakdowns) in a 1,000 foot section.

u
np
p

The u chart is only the most appropriate when the statistic of

interest is the ratio of the number of occurrences of an attribute to
the area of opportunity which varies from subgroup to subgroup.
Here the area of opportunity (subgroup size) is constant (1,000
feet).

c
The np chart is appropriate only when the statistic in question is
the number of nonconforming items out of the total number of
items inspected and the subgroup size is constant.
The p chart is appropriate only when the statistic in question is the
proportion of nonconforming items out of the total number of
items inspected.
62.

A manager is struggling to meet customer expectations in

processing orders timely. The manager has asked the team
how to reduce lead time with kaizen. What would be the least
effective method to reduce cycle time?
Focus on working each step faster; the problem is
unimportant.
Reduce interruptions and delays between steps.

Correct! Trying to work each step faster is not the best approach as
it may not be sustainable and doesn't reduce any barriers or
constraints that may be affecting the process.
Reducing interruptions or delays can improve the continuous flow
of work which will help to reduce lead time.
Wait times and transport times can sometimes be reduced by
changing the sequence of steps, which can help decrease lead
time.

Change the sequence of steps.

Look for ways to perform steps in parallel.
63.

The most effective method for ensuring similar products are

segregated during manufacturing in the same production area
is to:
Install painted lines between work stations running similar
products
Use a unique color coded label to identify each similar
product
Schedule and run production of only one similar item at a
time
Train personnel to recognize the differences between
products

Many processes are worked in a serial approach that results in the

cycle time for the entire process being the sum of each step;
finding ways to work in parallel can significantly shorten lead time.
Correct!
Scheduling and running production of only one similar item at a
time prevents the possibility of mixing items if only one is being
manufactured at a time and presents the cleanest solution to the
problem. The possibility of mixing product is eliminated by this
method.

Scheduling and running production of only one similar item at a

time is a more effective method since only one similar item is being
produced at a time

64.

n DOE, which of the following best describes a

"blocking factor?"

Correct! A blocking factor limits the number of experiments to a block, e.g., time
in a day or shift, size of a batch, machine capacity.

Factor thought to have an effect but not easily

controlled

Blocking factor is included in the design but it has no impact on response level.

Factor selected for greatest response

Factor excluded in design
Factor identified for least response
65.

n the hypothesis test for means, if the test statistic

is in the reject region, then:

Reject the null hypothesis.

Accept the null hypothesis.

Reject the mean.
Do not reject the null hypothesis.
Reject the null hypothesis.
66.

The number of blemishes in the paint finish on the

hood of a car is being monitored. Each day a
sample of between 20 and 25 hoods is inspected. To
monitor the number of blemishes per hood in the
daily sample, which control chart is most
appropriate to use?

Correct! The u chart is appropriate when the statistic of interest is the ratio of
the number of occurrences to the area of opportunity. In this case it is the
number of blemishes divided by the number of hoods inspected. Here the
area of opportunity (subgroup size) varies because a sample varies between
20 and 25 hoods.

p
c

The p chart is appropriate only when the statistic in question is the proportion
of nonconforming items out of the total number of items inspected.

np
u

The c chart is appropriate only when the statistic of interest is the number of
occurrences of an attribute in a given area of opportunity, where the area of
opportunity remains constant for all subgroups. This case of interest is the
number of blemishes divided by the number of hoods inspected. Here the
area of opportunity (subgroup size) varies because a sample varies between
20 and 25 hoods.
The np chart is appropriate only when the statistic in question is the number
of nonconforming items out of the total number of items inspected and the
subgroup size is constant.

67.

The number of imperfections on rolls of steel is

being monitored on a u chart. Each day, the
number of imperfections found and the number of
rolls inspected is recorded. The data so far are as
follows:

Correct!
is the sum of the imperfections divided by the sum of the rolls inspected.
Sum or imperfections= 5 + 10= 15
Sum of the rolls= 2+ 3= 5

Imperfections: Day 1 (5) + Day 2 ( 10)

U-bar = 15/ 5= 3
Rolls: Day 1 (2) + Day 2 (3)

68.

On a control chart, 15 consecutive points in a row falling

within one sigma from the center line indicates which of
the following?

Correct!
A run of 15 points in a row within one sigma of the e center line is
statistically unlikely, time to investigate.

You should investigate the cause; The process is out of

control because this is statistically unlikely.

Something has changed in the process and it may have improved the
process or it may be someone is making up the data, either way, we
should investigate because statistically speaking the process is not in
control.

You should investigate why the process variation has

increased.

The process variation has decreased.

You should investigate why the mean has shifted 1.5 sigma.
You should do nothing, the process is in control and the
parts are in spec.
69.

A one-sample T study was performed on a supplier's lot:

T study = 10 vs 10 and Alpha Value=0.05
The mean of 10 samples tested is 9.85.
The 95% confidence interval of the population mean is
9.75, 9.95.
P-Value = 0.046.
A discussion with the process expert determined that the
population mean can vary from 9.7 to 10.1 without
impacting the product performance. Choose the best
course of action:
Fail to reject the null hypothesis since it is not statistically
significant and reject the lot irrespective of practical
significance.
Reject the null hypothesis since it is statistically significant
and reject the lot irrespective of practical significance.
Reject the null hypothesis since it is statistically significant
and accept the lot since it is not practically significant.
Fail to reject the null hypothesis since it is not statistically
significant and accept the lot since it is not practically
significant.

Since the P value is lower than the Alpha value, the null hypothesis of
= 10 vs 10 is rejected. However, due to the practical significance
that there is no impact to the product, the supplier's lot is accepted

70.

An operator is expected to assemble certain parts without

error. Each assembly may be different depending on the
customer order. Which of the following is the best example
of error-proofing for this situation?

Correct!---Light-up bins that contain only the parts needed for

assembly will make it easier to know which parts go with which
assembly.

When the operator begins putting together an assembly, he

or she is given a list containing only the parts for that
assembly.

A list still allows for confusion as to which parts are in which bins;
therefore, errors could still be made.

Standardized work instructions are written and posted at

the operations. These contain instructions for all the
assemblies.
When the operator begins putting together an assembly,
only the bins containing the parts for that assembly light
up.

Written and posted standardized work instructions still allows for

confusion as to which parts are in which bins; therefore, errors could
still be made.
Although training is always helpful, it does not prevent errors from
occurring.

Each operator is trained on which parts go into each

assembly being made available to customers.
71.

A point outside the control limits is a signal of the likely

occurrence of:
A trend

Answer= Special-cause variation

A trend is a continual movement in one direction, for example, six
points in a row constantly increasing.

A chance cause
Special-cause variation
Common-cause variation
72.

The process drift in machining operation is said to be

normally distributed with a mean of 46.23 seconds and a
standard deviation of 3 seconds. What is the probability
that the drift of this operation will be less than 52.81 second
Where the next measurement is taken?
0.0143
0.9857

Correct! 0.9857 represents the area under the curve to the left when
Z is 2.19, and represents probability of an occurrence that is less than
the value Z.

0.0143 represents the area under the curve to the right when Z is
2.19 and represents probability of an occurrence that is greater than
the value Z (This is the compliment of rational 4, the candidate must
understand the difference when calculating z and using the z tables
to determine the area under the curve).

0.4857
1.00
73.

A quality team has finished a brainstorming session and

would like to document the results. The best tool for this is
which of the following?

Correct!---A cause and effect diagram documents the final list of

causes from a brainstorming session.

Pareto chart

The Pareto chart separates the "vital" few from the "trivial many." It is
created based on data and not brainstorming results.

Check sheet
Dot charts are used to display the values of categorical data.
Cause and effect diagram
Check sheets are used for data collection.
Dot chart

74.

Since experimental error is almost invariably present, what is

required to increase the precision of estimates of the effects?

Correct! Replications are test trials that are made under

identical conditions.

Replication

Redundancy is product- or process-focused.

Redundancy

Regression is associated with an analysis technique.

Random sampling
Regression
75.

A Six Sigma Green Belt is creating a control plan for a manufacturing

process. What should the Six Sigma Green Belt consider?
What is the delivery rate for the material?

Correct! The packaging may also need to be inspected.

The number of parts to inspect is in the control plan, not
the production rate.

How many parts will be produced per hour?

Where is the material stored?
Are packing issues for the part addressed?
76.

A Six Sigma Green Belt is evaluating the correlation between two

variables. She has heard that it is critical to be aware that correlation
does not always imply causation. The best way to determine if there is
a causation is to:

Causation cannot be detected from a correlation

coefficient.The best way to be certain that causation is part
of correlation is to conduct an observational study or welldesigned experiment.

Conduct an observational study or a well-designed experiment

The best way to be certain that causation is part of

correlation is to conduct an observational study or welldesigned experiment.

Plot the variables on a scatter plot

Calculate the correlation coefficient, and if over 1, it is causation
Make the independent variable the X-Variable
77.

Sources of unscheduled downtime include which of the following?

Correct! Machine breakdown and part shortages cause

unscheduled down time.

Machine breakdown and part shortages.

Quality failures and part shortages.
Setup time and maintenance.

Part shortages cause unscheduled downtime, but quality

failures are not a source of unscheduled downtime.
Setup time is a source of unscheduled downtime, but
maintenance is scheduled.

Machine breakdown and maintenance.

78.

A spaghetti or work-flow diagram is used to identify which one of the

following types of wastes?
Defects
Motion

Correct!
The movement of paper, a file, a person, a piece of
information, or materials can be measured by a spaghetti
diagram.
Overproduction measured with an analysis of work-inprocess (WIP).

Waiting
Waiting = cycle time study
Overproduction
Yield rate= defects

79.

A study compared a ranking of the tax system friendliness of all 50 states to the
number of businesses per million population per state. A regression analysis
showed the correlation coefficient was 0.108. What conclusion can be made
from the analysis?

There is a low r indicating a low association

between variables.

Tax system friendliness is negatively correlated to the number of businesses

There is little if any association between tax system friendliness and the number
of businesses
Tax system friendliness predicts more privately held businesses
A strong association between tax system friendliness and the number of
businesses
80.

A supervisor has asked his Green Belt to compare the average daily scrap value
from the first shift to the average from the second shift to determine if there is a
difference of more than $1.00 with 95% confidence. The Average daily scrap for
both shifts has been $25.76 for the past year with a day to day standard
deviation of $7.07 for the past year with a normal distribution. The supervisor
believes the two shifts are contributing about the same amount of scrap but
wants the answer next week so he can appraise his team leaders.

The one sided Z score for = 0.05 = 1.96

Sample = n = (Z2 2)/((1.0)2) = (1.96)2 * (7.07)2 /
(1.0)2 = 192

What do you tell him?

It will take 14 Days to get the data the supervisor wants

You can give him the results in 7 days with 56% confidence
You can produce the results in 8 days
Based on the confidence interval wanted and the significant difference of $1.00,
a sample of 192 days pf production would be required which is not practical.
81.

Suppose you have completed an Ishikawa diagram. Which is the best way to
search for true root causes out of all the possible causes identified?
Use a multi-vote process to select highly likely root causes and then use forcefield analysis on them. Gather data to confirm that the selected Xs affect the Ys
of concern. If none of the investigated Xs turn out to significantly affect the Ys,
then return to the fishbone and start over.
Only look at the deepest level on the fishbone.
Gather data to confirm/deny each identified possible cause on your fishbone.

Correct!
Start with investigating the most likely causes,
prioritizing them in order of likelihood. You
need to confirm with data the root cause nature
of suspected X. If none of them are highly
effective in moving Y then you should go back
and review your fishbone and start the multivote process again, removing those Xs already
disproven.
The true root cause is almost always deeper
than the major bones, which are the 5Ms and E.

Investigate the Xs on the major bones. The root cause will be at that level.
The remaining choices are too burdensome to
conduct.

82.

Suppose your team has just completed a relationship matrix on

a current process problem. The team is having difficulty
identifying where to start searching for the root cause. Which of
the following is the best way to guide team members?

Correct!
These root causes seem to affect more than one problem so
there is a lot of potential to reduce waste if you can identify how
to mitigate or prevent these issues.

Explore the cells where the relationship between potential root

cause (X) and outcome (Y) is strong. If there are any rows that
have more strong relationships in them than others guide the
team to consider those root causes (Xs) first.

Choice B= Remember that if your team is cross-functional, as it

should be, then the combination of all the experience and
knowledge will lead to better solutions. Also, this approach is
resource-intensive. It is better to prioritize the potential causes
and work on them one or two at a time.

You need the team to break up and work as individuals or small

groups on each strong relationship identified.
Let them figure it out. Just make sure that everyone gets a
chance to talk.

C= A good facilitator has a plan when the team gets stuck. It is

your job to help them move forward.
D= If it doesn't have a high impact you really shouldn't do it. It's
a waste of resources.

Look for low hanging fruit, i.e., easy fixes and Just Do It, whether
it has a high impact on the Ys.
83.

A team is faced with a clear need to rapidly improve a

production process and upper management has challenged the
team to come up with a workable solution within a 48-hour
timeframe. This would be an appropriate scenario for applying
the concept of which of the following?

Correct! Kaizen blitz----A rapid, time-limited solution is the key to

this question and this approach

The PDCA cycle is a useful continual improvement tool, but it

does not meet the timeframe requirements of this situation.

Trend analysis
Kaizen blitz
Poka-yoke

Poka-yoke refers to mistake-proofing. While the term does apply,

it is not the best solution of the possible answers.
A trend analysis involves collecting information to identify
trends. The above situation requires a more rapid approach.

PDCA cycle
84.

A total of 4000 closures were manufactured on machine #7. 200

closures had one defect each. A total of 3800 closures were
packed.
What are the defects per unit (DPU) and throughput yield?

DPU is determined by 200/4000 = 0.05 and throughput yield is

determined by 1.00 - 0.05 = .95 x 100 = 95%

1 DPU and 99% throughput yield

0.0526 DPU and 94.7% throughput yield
0.05 DPU and 95% throughput yield
1.05 DPU and 95% throughput yield
85.

Total Preventative Maintenance is used to watch for which of

the following?

Correct!
TPM watches for visible or audible symptoms of machine failure

Symptoms of machine failure.

Overproduction.

SPC is used to detect problems before parts go out of

specification.

Ensuring quality checks are performed.

Overproduction is an element of non-value added activities

Signs a part will go out of specification

86.

Total Productive maintenance is used to do which of the following?

Correct!
The purpose of TPM is to reduce machine downtime.

Prevent quality failures

Correct machine failures
Reduce machine downtime
Improve product quality
87.

Twenty ports in a housing may each have dimensional errors (defects). A

control chart is being set up to monitor the number of unsatisfactory ports
in each housing, where each housing is a subgroup. Which control chart is
most appropriate to use?
np
p
u

88.

The np chart is used when subgroup sizes are

constant and you are measuring defectives.

The p chart is used when subgroup sizes vary and

you are measuring defectives.
The u chart is used when subgroup sizes vary and
you are measuring defects. In this case, subgroup
sizes are constant.

The c chart is used when subgroup sizes are

constant and you are measuring defects.

Two machines are to be compared. A sample of 100 pieces of manufactured

product is taken from each machine and their measurements recorded
each shift. The most appropriate control chart to compare the results from
the two machines over time is an:

Correct! An Xbar and s chart is appropriate for the

large subgroups. The part of the chart will compare
the averages, and the s part of the chart will
compare the standard deviations.

I chart
MR chart
Xbar and R chart

An I chart is designed for individual measurements

from a process in time (or space) order.
The MR chart monitors the moving range (spread)
between individual measurements.

Xbar and s chart

With such large subgroups (100), the R (range)
values are not useful.
89.

Using a template to eliminate the possibility of error at a drilling step

would be an example of which of the following?

Correct!--Poka-yoke refers to error-proofing an

operation or step.

5S

Kanban is a resupply procedure.

Kanban

5S is a system for keeping an area tidy.

Poka-yoke

Standard work refers to keeping a repetitive task

the same through good work instructions and
training.

Standard work
90.

A visual workplace provides which of the following?

A map of the value stream
A method to ensure that mistakes can't occur.
Identification of the status of material that you can physically see.
Continuous, incremental improvements.

A visual workplace provides information on the

status of material.

91.

What assumption can be made if an organization is effectively using lean

thinking and applying lean tools to reduce waste throughout the value
stream?

Correct! A lean enterprise organization

effectively uses lean thinking and applies lean
tools to reduce waste throughout the value
stream and offer value to its customers

It can be considered to be a traditional manufacturing business.

It can be considered to be a house of quality.
It can be considered to be a lean enterprise organization.
It can be considered to have a system of profound knowledge.
92.

What can workers do to meet time requirements in a continuous flow

environment?

House of quality is the first diagram used in

quality function deployment (QFD) to plan the
design or improvement of a product or service. It
combines several matrices and charts into one
massive diagram.
Correct!
Workers should communicate with each other to
maintain the required speed.

Work faster.
Work in only one position the entire time.
Communicate with each other.
Fix problems as fast as possible and restart the machine.
93.

What is a single level assigned to a single factor during an experimental run?

Treatment

Correct! A treatment is a single level assigned to a

single factor during an experimental run of a
designed experiment.

Block
A treatment is applied to a unit.
Version
Unit
94.

What is the fewest number of samples required to achieve a confidence level of

99% that when fed a new diet, the average weight gain of a sheep over a 90 day
period had increased by 5 pounds over the current average of 20 pounds? The
weight gain per sheep is normally distributed with a standard deviation of 4.3
pounds.

A block is a factor that has influence as a source

of variability.
Correct!
Sample = n = (Z2 2)/(E)2)
Where E = the minimum value to be

31
101
71
123
95.

What is the systematic error that contributes to the difference between a

population mean of measurements and an accepted reference value called?

Correct! Bias is systematic error and not random

error that is difficult to control in measurements.

Bias
Skew is a measure of symmetry of a distribution.
Consumer risk
Producer risk
Skew

Consumer risk is the probability of accepting a

bad lot.Producer risk is the probability of not
accepting a good lot.

96.

When any statistic is used to estimate the

parameter, what property of the statistic is
called the standard error:

Correct!
Standard Deviation of the statistic is called the standard error.

Variance
Parameter
Mean
Standard Deviation
97.

When calculating a correlation coefficient,

which of the following steps is performed
first?

For the first step, one would calculate the mean for all x-values and the mean for all yvalues

Calculate the mean for all x-values and the

mean for all y-values

Calculating the standard deviation for all x-values and the standard deviation for all yvalues is the correct 2nd step. Calculating the standard deviation for all x-values and
the standard deviation for all y-values is the correct 2nd step

Sum the values and divide the sum by Sx x

Sy

Sum the values and divide the sum by Sx x Sy is the correct 5th step

Calculate x- x-bar, and y- y-bar for each pair

(x.y) and then multiply those values
together
Calculate the standard deviation for all xvalues and the standard deviation for all yvalues
98.

When designing a cause and effect matrix a

team should do which of the following?
Number the scales for the process input and
process output variables from 1 to 10
inclusively.
Select a member to reduce the process
input and process output variables to a
reasonable number using his/her subject
matter expertise.
Use some deciding method to help the
team identify the key process input and key
process output variables for the row and
column headers.
Place all the brainstormed process input
and process output variables in the row and
headers respectively.

Correct!
The first step is to brainstorm all the process input and output variables. After
discussions with the team members, a multi-vote or other deciding process should be
used to narrow the lists to the key candidates.
Because this is a team, it is better to use all of the brainpower to help narrow the
choices versus selecting a single member to make the final decision.
If you place all the brainstormed inputs & output not rows and columns-----You are
likely to get more input and output variables than are feasible to use in the cause and
effect matrix. Completing it would become cumbersome and would discourage the
team with the paperwork.

99.

When interpreting the results and preparing the report from a

design of experiment, which of the following is important when
presenting the findings?

Correct! The conclusions must be backed by the data from the

experiment performed. So limit conclusion to object summary of
evidence

Present all available sources of information.

In the design of the experimental program, stating possible

interrelationships of factors and alternative outcomes is
performed DURING the DOE and not at the reporting stage.

Limit conclusions to object summary of evidence.

Outline possible alternative outcomes.
State possible interrelationships of the factors.
100.

When is it appropriate to use a block factorial design?

When the number of runs is too large to be carried out under
homogeneous conditions.
When a more illustrative design to display factors under the
experimenter's control influences the response.
When there are many factors and levels and it is impractical to
run all combinations.
When there is a need to study relative variability instead of
mean effect of sources of variation.

Correct! A situation in which the number of runs is too large to

be carried out under homogeneous conditions is appropriate
for a block factorial design.

When a more illustrative design to display factors under the

experimenter's control influences the response, a response
surface application is appropriate.
When a more illustrative design to display factors under the
experimenter's control influences the response, a response
surface application is appropriate.
A nested design application is appropriate when there is a
need to study relative variability instead of mean effect of
sources of variation.

101.

When manufacturing a product, which of the following options

is an element of continuous flow?

Correct! Takt time begins the movement in continuous flow and

sets the pace

Takt time

Muda is waste; this may be reduced as an effect of continuous

flow, but it is not a part of continuous flow.

Kaizen
Kaizen is a method of gradual improvements.
Mass production
Muda
102.

When using a factorial design of experiment with k-factors (each

factor at two levels), what tool can be utilized to detect an
aberrant value (very low probability of occurrence)?

Correct! A half-normal plot can be used to detect an aberrant

value in this case.
The Youden plot shows the systematic differences.

Youden plot
Yates' algorithm
Half-normal plot
Response curve

The Yates' algorithm is a rapid method for obtaining estimates

of main effects and interactions for two-level factorials.
A response curve is utilized particularly in factorial experiment
with two factors to show presence or absence of interaction.

103.

Which chart would you use to track the number of defects

found per identical printed circuit board inspected?

Correct! C-charts!
These charts are concerned with the counts of whether an attribute is
present (attribute data) and the sample size is constant.

np chart
u chart

np Charts are used to study the number of defective items.

c chart

U charts are used to monitor the proportion of defects for example

defects per 1000 opportunities.

X Bar R chart
The X bar R chart is a chart used for variables data (also called
measurement data).
104.

Which hypothesis test can be used to determine if the

variance calculated from machine #1 data on Shift A is the
same as on machine #1 during shift B?

Correct!
An F-test compares the variance from one population (Shift A) to the
variance from another population (Shift B).

Chi-Square Test
z-Test
F-Test
t-Test
105.

Which of the following best describes a controlled or

uncontrolled variable whose influence on a response can
be studied?

Correct! A factor is a variable that can have influence on a response.

A treatment is a single level assigned to a single factor during an
experimental run.

Level
Treatment
Factor

Resolution is a term that describes the degree to which factors are

aliased (or confounded) with interactions.
Level refers to the values or settings selected for the factor being
examined in the experiment

Unit
106.

Which of the following best describes the structure of a

response surface design of experiment?

Correct! The response surface design of experiment has the following

structure= factor setting are viewed at defined points.A map can be
constructed as a result of the defined points

Each treatment occurs one in every row.

Several factors are investigated.

Mixed designs employ the structure where factor settings are

constrained.

Factor settings are viewed at defined points.

Fractional factorial= Several factors are investigated.

Factor settings are constrained.

A row-column design also referred to as a Youden square= each

treatment occurs one in every row.

107.

Which of the following describes the three

components of standard work?
Standard deviation, standard inventory, and
standard sequence.

Correct! The three components of standard work are standard time,

standard inventory, and standard sequence.

A standard operating procedure may document the steps for standard

work, but it is not a component of standard work.

Standard deviation, standard operating procedure,

and standard sequence.
Standard time, standard inventory, and standard
sequence.

Standard deviation is a statistical concept and not a component of standard

work.

Standard time, standard operating procedure, and

standard sequence.
108.

Which of the following elements should be included

in a control plan?

A control plan is used for inspection activates, not the project's control
phase.

Plan for the control phase

The project charter is a component of the Define Phase and not typically
included in the control plan.

Project Charter
Tests for significance

Tests for significance are usually used in the Analyze Phase and not an
element of the control plan.

Identified sample sizes

109.

Which of the following financial metrics provides the

best measure of the long-term success of an
organization's Six Sigma program?
asq/learn_check.gif
Cost of Poor Quality

Cost reductions related to reductions in internal failures, external failures,

appraisal cost, prevention cost and the cost of non-value added activities
are a direct, and the best measure of improved performance related to Six
Sigma projects.
Close

Cost Benefit Analysis

Net Present Value of Project Outcomes
Market Share
110.

Which of the following hypothesis test can be used to

determine if the variance calculated from machine
#1 data on Shift A is the same as on machine #1
during shift B?

An F-test compares the variance from one population (Shift A) to the

variance from another population (Shift B).

The t-Test compares sample means.

t-Test
A z-Test is a test for two means.
F-Test
Chi-Square tests are for normality.
Chi-Square Test
z-Test

111.

Which of the following is a group of experimental

runs conducted under relatively homogeneous
conditions?
Response variable
Interaction

Correct! A block is a factor in an experimental program that has influence as

a source of variability under homogeneous conditions.
A response variable is the variable being investigated in the design of
experiment.
Interaction is a condition where the effect of one factor depends on the
level of another factor.

Experimental error
Block
112.

Which of the following is a visual comparison of the

effect of each of the factors by displaying the means
of all factors at each factor level?

Experimental error is variation caused by extraneous variables. It is often

called experimental noise.
Correct!
The example above defines multi-vari studies.

DOE
FMEA
Multi-vari study
Binary logistic regression
113.

Which of the following is the option that best fits the

sequence for implementing 5S?

Correct! The proper order is: remove unneeded items, arrange items, clean,
develop standardization, and sustain the improvements

Remove unneeded items, arrange items, develop

standardization, clean, and sustain the
improvements.

Cleaning should happen before standardization is developed.

Clean, develop standardization, remove unnecessary

items, arrange items, and sustain the improvements.
Clean, develop standardization, arrange items,
remove unnecessary items, and sustain the
improvements.
Remove unneeded items, arrange items, clean,
develop standardization, and sustain the
improvements.
114.

Which of the following situations illustrates the lean

concept of "pull"?

Correct!---The pull comes from the downstream operation signaling that it

needs what is being produced upstream.

Nothing is produced by the upstream operation

until the downstream operation communicates it is
ready.

The upstream operation sets the pace for the downstream operation's
production is rather a push situation which typically leads to large amounts
of work-in-process inventory and increased costs.

The upstream operation sets the pace for the

downstream operation's production.

Here the upstream operation is producing to an anticipated need. This

often leads to a push situation such as excess inventory and costs when
downstream disruptions occur.

The upstream operation produces to the schedule

provided by the downstream operation.
The upstream operation's production is
synchronized to provide the downstream operation
just-in-time

Here the upstream operation is anticipating the downstream need instead

of responding to a clear signal.

115.

Why can items such as bins, floors, benches and racks be used as part of a visual factor?
The items can be kept clean and orderly.

Correct!These items can be

used to communicate
information as part of a visual
factory.

These items can be used to communicate information.

Items such as bins and benches can be arranged by order of operation.

Visual factory is used to

communicate, not store things.

Items such as floors, bins benches and racks can be used for storage.
116.

Why would a Six Sigma Green Belt create a control plan after improvements are implemented?
To identify potential risks in a process.
A control plan is required during a Six Sigma project.
To systematically identify and resolve out of control conditions.

Correct! A control plan is used

identify when out of control
conditions occur.
Feedback for distractor 2 SPC
can detect a potential problem
before it occurs.

To identify failures before they occur.

117.

A work team wants to set up an X bar R chart for the finished length of tubes used in a camera
tripod. They have data from 25 samples of 4 pieces each, What statistics do they need to
calculate before they can set their control limits for their X bar chart?
The average of the sample averages for finished length and average range across the samples.
The average of the range for finished length.
The average of the sample averages for finished length and average range across the samples,
and the square root of the sample size.
The average of the sample averages for finished length and the standard deviation across the
samples.

Correct!
You need to know the grand
average finished length and
the average range.

118.

An X bar control chart used in a machining

operation is trending toward the upper control
limit for the past 10 weekly samples. Which of the
following changes is the most likely cause of this
trend?

Correct! A trend would be expected when something on the machine is

wearing out, which could be caused by lack of maintenance.

The plant start time was changed from 8:00 AM to

7:00 AM 10 weeks ago.

A more repeatable measuring device would reduce common cause variation in

the measurements and reduce the range. If it did produce a change in the
average, it would be a step function, not a trend. Since it happened only 3
weeks ago, it does not account for the 7 points in the trend before it was
introduced.

The sample size for X bar was changed from 5

pieces to 8 pieces 12 weeks ago.

Changing the sample size would not cause a trend.

The semiannual preventive maintenance action

due 15 weeks ago was skipped.
A new measurement tool that is more repeatable
was introduced to measure the samples 3 weeks
ago
119.

An X Bar R control chart over time shows that the

process average is centered in between the spec
limits, and the process average range is greater
than the distance between the upper and lower
spec limits. Which statement below is the most
correct?

Correct! The process may be in control, but the customer requirements are not
being met because some points fall outside the upper or lower spec limit. [
Range > (USL-LSL)] Reducing the variation in the process will reduce the
range. If the variation is due to special causes, then removing them will bring
the process into control and reduce the variation. The process mean is already
centered; hence it is proper to focus on variation.

The process does not predictably meet customer

requirements; the process variation needs to be
reduced.

The spec limits should reflect the needs of the customer, they may be too tight
but we cannot tell that from the information.

The spec limits are too tight.

The process is not in control.
The process is in control
120.

You are a green belt planning a kaizen event to

reduce cycle time for trauma patients in a busy
emergency room. You think several different
departments may be involved. What approach
might be most useful to help identify all the
stakeholders needed to attend the event?
Announce the kaizen event and include a sign-up
sheet.
Sketch out a high-level process map.
Ask an emergency room supervisor.
Create a SIPOC.

Correct!
Create a SIPOC in addition to providing a high-level scoping of the process for
the event to help identify all stakeholders that touch the process.
High- level process map ---While it is part of a SIPOC, it does not identify
stakeholders

121.

You are conducting an experiment to compare the means of two different

treatments of a product. You have computed a Z test statistic of 1.645 and reject the
null hypothesis that the two means are equal. What is the probability that you have
made a type 1 error?

The Z statistic of 1.645 corresponds to a

probability of a type one error in each
tail of a two tailed test of /2 = 5 %
Therefore = 10 %.

90%
95%
10%
5%
122.

You are in the medical device business and the cost of a type 1 error in your
experiment is high since human lives are at stake. Which combination below gives
you the lowest probability of a Type 1 error?
= 0.95, = 0.90
= 0.10, = 0.01
= 0.95, = 0.05
= 0.01, = 0.10

Correct!
, The probability of a type one error is
1%.