Quiz2 Sample Question

Question 3 (2 points) An effective way to document and communicate the current state of a process is to develop a process map or diagram. () True () False

Question 6 (2 points) A sequence of 4 operations has first time yield rates as follows: 91%, 85%, 92%, and 89%. The rolled throughput yield (RTY) is: () 89% () 72% O 92% (O 63%

Question 9 (2 points) Saved In the current-state process flowchart, if there is a long delay between process steps being mapped, should you; @ change the flow to avoid the delay Q report the delay to management Q disregard the delay and focus on value-add process steps Q include a delay symbol in the process map

Question 12 (2 points) Current State process maps: @ Are a management tool to promote Lean Six Sigma Q Help verify the problem exists G Should be completed before meeting with operators to help demonstrate the problem O Should be completed following the Analyse phase

Question 15 (2 points) Cause and Effect (C&E) diagrams; Q Help predict the outcome of process changes Q Identify which processes are responsible for 80% of the problems Q ldentify the processes that have the highest impact on customer CTQ's Q Identify the RPN (Risk Priority Number) for each process step

Question 18 (2 points) When developing a data collection plan in the Measure phase, three sources of process data that should be considered are; Q Previous State, Current State, Future State Q Discrete, Continuous, Analog O Engineering, Quality, Sales Q Process Inputs, Outputs, and internal Process Controls

Question 21 (2 points) Once a fishbone (Ishikawa) diagram has been completed for a given problem, the next logical step would be: Q Continue building fishbone diagrams for each process step O Organize the fishbones using an Affinity map Q Use the fishbone diagram to create standard work instructions Q Create a data collection plan based on the potential root causes listed

Question 22 (2 points) The Pareto (80:20) concept refers to the idea that: Q 80% of inspection should be done in-process, 20% at final Q 80% of processes are flawed O 80% of products are rejected by 20% of the customers Q 80% of problems are caused by 20% of the factors

Question 23 (2 points) This is a standard flow charting symbol for: O Decision O Storage Q Step, Process, Operation O Delay

Question 24 (2 points) What is the best way to build a fishbone diagram? Q with Senior Management & Executives O using Technical Process Manuals Q with Subject Matter Experts Q watching YouTube videos of the process

Question 25 (2 points) An operator travels back and forth between their machine and a toolbox across the isle several times in a shift. Is this an example of: () Value Add Q MURI Q MUDA () Good Exercise

Question 26 (4 points) Six Sigma percentage yield is ()99.977 ()99.38 (1933 Q 99.99966

Question 27 (2 points) Select all that apply - FMEA provides a structured approach to: D Prioritize the actions that should be taken to decrease the risk of failure D Identify ways in which a process or product can fail D Estimate the risk associated with each specific failure D Document the formal risk review and the actions taken to lower the risk

Question 28 (2 points) The main purpose of the Measure phase in the DMAIC problem solving road map is to: Q Measure customer satisfaction to generate CTQ's Q Measure current state of the process in preparation for the Analysis phase Q Create improvement Measures that will reduce waste O Verify the Measurement system is accurate and precise

Question 29 (2 points) This is a standard flow charting symbol for: Q Storage Q Decision () Delay Q Step, Process, Operations

Question 30 (2 points) Which of the following is an example of continuous variable data? Q Percentage of rejected parts after painting () Paint colour O Paint chips per unit Q Thickness of paint layer

Question 31 (2 points) Which of the following provides a graphical representation of travel distances and travel patterns within a process. Q Value Steam Map Q Swimlane Diagram Q SIPOC Chart () Spaghetti Diagram

Question 32 (2 points) Match the following - I Identifies the inputs and outputs of a process or process sequence Shows travel paths and distances for people or material Good for transactional processes, showing decisions and interactions between different functions To see and understand the flow of material and information including lead time and inventory SIPOC Spaghetti Diagram Swim lane Process Flow Value Steam Map

Question 33 (2 points) Based on the FMEA, how should you select which failure modes to assign actions to? Q Assign actions to all potential failure modes O Assign actions to top 3 failure modes Q Assign actions to failure modes with RPN over an acceptable limit Q Assign actions to failure modes with RPN of 9 or higher

Question 34 (2 points) If during the Measure phase, you can't verify the problem, should you: Q Proceed to the Analyse phase with the data collected O Report that the problem has been resolved and proceed to the Control phase O Take additional measurements until the problem is verified O Return to the Define phase to clarify the problem

Question 35 (5 points) A process has defects described as Types A-D. Data was collected for the number of defects (D) and the number of units (U). OP is the number of opportunities per process step. Where in the process should the improvement efforts be focused? Step |Defects (D)|Units (U)| Opps(0) | TOP (UxO) |DPU (D/U)|DPO (DPU/O)DPMO (DPU*1,000,000) A 20 326 91 B 349 84 C 36 42 D 67 742 49 O Process C Q Process A and B Q Process B O Prrocess D Q Process A

Based on this C&E Matrix, which process has the highest impact on customer CTQ's? Rating of Importance to Customer Kalakand Chef Knives Customer = Conestoga Chef School © 10 s Custor Correlation Ranking Guideline: 0 = No Correlation 1 = the input remotely affects the cutomer requirement 2 = the input has 3 moderate effect on the customer requirement 2 = the input has a direct/strong /mpact on the customer requirement 681-865HRC|High Toughness|Balanced Kr Process Input Process Step 1 natural gas harden e e 0 2 freezer deep freeze (quench) = 2 0 3 natural gas stress relief (temper) = e 0 - grind wheel concave grind 3 3 El 5 sheet steal purchase stesl = 2 0 6 buffing whee! robotic buff and polish 3 3 3 7 sharpening stone honing (sharpen) 3 3 3 8 buffing whee! buffing (remove burr) 3 3 3 2 laser program lazer etch 3 3 0 10 drawing/standards inspect 3 3 3 1 buffing whee! buff (surface imperfections) 0 0 0 12 sleeve & box package 0 0 0 4 > O Concave Grind Q Stress Relief O Hardening O Purchased Steel

Question 37 (2 points) An effective way to document and communicate the current state of a process is to develop a process map or diagram. () True O False Question 38 (2 points) Fishbone (Ishikawa) Diagrams are useful because; O They rank all potential causes by calculating the Risk Priority Number for each O They limit the number of potential causes to the 20% most likely ones They don't require a detailed knowledge of the process and only need 1 or 2 people to complete O They help organize a brainstorming session and identify many possible causes Question 39 (2 points) Where would you list "low carbon content in steel" on a fishbone diagram? O Method O Material Q Environment Q Manpower

Question 40 (2 points) If the effect of a given failure mode is significant with low chance of detection, would you expect an FMEA to show: O A low Detection Value for that failure mode O A long list of controls for that failure mode O A low Risk Priority Number (RPN) for that failure mode O A high Risk Priority Number (RPN) for that failure mode Question 41 (2 points) If a fishbone diagram highlights "incomplete/insufficient tempering" as a potential root cause, which would be the best data to collect; O Number of parts completing the tempering process O Quench time & temperature O Furnace time & temperature O Furnace make & model Question 42 (2 points) In a fishbone diagram, one common "M" that is considered is: O Motivation O Measurement O Metrics O Mistakes

Question 43 (2 points) Three key decisions for preparing a data collection plan are: O What, How, Who O Past, Present, Future O When, Where, Why O Cost, Quality, Time Question 44 (2 points) What impact does increasing the likelihood or effectiveness of detection have on the RPN/Risk score in an FMEA? O RPN will decrease O RPN will increase O Severity and Occurrence will decrease O Detection has no impact on RPN