Six sigma belt has a 2 ^ (5-2) fractional factorial design. Only 2 of the 5 factors remained important after the factorial analysis. Escalation of this DOE to an optimization model will be best accomplished by:
a. performing a new full factorial of the 2
Six sigma belt has a 2 ^ (5-2) fractional factorial design. Only 2 of the 5 factors remained important after the factorial analysis. Escalation of this DOE to an optimization model will be best accomplished by:
a. performing a new full factorial of the 2
At what 5S step would standards for each of the 5 steps be established?
At what 5S step would standards for each of the 5 steps be established?
Sustain = answer
Essence of kanban concepts includes what?
a. delivery of components and products ahead of need
b. minimal storage in production areas
c. minimal distress in the production system when a machine failure occurs
d. wide applicability to repetitive and non-re
Essence of kanban concepts includes what?
a. delivery of components and products ahead of need
b. minimal storage in production areas
c. minimal distress in the production system when a machine failure occurs
d. wide applicability to repetitive and non-re
Which one of the following is single factor experiment containing specific nuisance factors?
a. Graeco- Latin square
b. Fractional Factorial
c. Latin square
d. Mixture design
Which one of the following is single factor experiment containing specific nuisance factors?
a. Graeco- Latin square
b. Fractional Factorial
c. Latin square
d. Mixture design
C= correct.
In this case, there are 2 factors that are not being studied, bu the
All of the factors that might be contributing to a production problem must be discovered. Which of the following problem-solving tools would be the best selection?
a. Pareto diagram
b. fishbone
c. histogram
d. control chart
All of the factors that might be contributing to a production problem must be discovered. Which of the following problem-solving tools would be the best selection?
a. Pareto diagram
b. fishbone
c. histogram
d. control chart
B= correct
Relational Matrix is a problem-solving tool which helps to:
a. Show cause-effect relationship between input and output variables
b. focus attention on problems in priority order
c. generate a large number of improvement ideas
d. determine where non-confor
Relational Matrix is a problem-solving tool which helps to:
a. Show cause-effect relationship between input and output variables
b. focus attention on problems in priority order
c. generate a large number of improvement ideas
d. determine where non-confor
When calculating the sample size for a DOE, one is actually calculating what?
When calculating the sample size for a DOE, one is actually calculating what?
Number of replications
the number of runs, factors, and blocks are all determined by the planning states of experimental design. Number times each experiment has to be conducted
If one is interested in reducing inventory and product lead times, what Japanese control terms would apply?
If one is interested in reducing inventory and product lead times, what Japanese control terms would apply?
Heijunka! ---means leveling of the production--this in turn, reduce inventory and lead times
What input categories are commonly used in cause-and-effect diagrams?
What input categories are commonly used in cause-and-effect diagrams?
Machines, material, and measurement
4 M of cause effect ----machine, material, method, manpower
5M and E method--includes measurement and environment
What is the relation between resolution III and confounded responses?
a. In resolution III experiments, there are no confounded interactions
b. In resolution III experiments, only interactions are confounded.
c. In resolution III experiments, all factors
What is the relation between resolution III and confounded responses?
a. In resolution III experiments, there are no confounded interactions
b. In resolution III experiments, only interactions are confounded.
c. In resolution III experiments, all factors
As with the 7 quality management tool, the Japanese concept of workplace organizations, 5S, has been Americanized. Which of the 5 is the hardest to find in the American system?
a. Seiri
b. Seiton
c. Shitsuke
d. Sieso
As with the 7 quality management tool, the Japanese concept of workplace organizations, 5S, has been Americanized. Which of the 5 is the hardest to find in the American system?
a. Seiri
b. Seiton
c. Shitsuke
d. Sieso
C= correct
There are several version o
A 3-prong 110 volt electrical plug is an example of:
a. yin and yang balance of alternating current wires
b. jidoka self-inspection process
c. Heijunka design improvement and optimization
d. poka-yoka permitting only proper plug insertion
A 3-prong 110 volt electrical plug is an example of:
a. yin and yang balance of alternating current wires
b. jidoka self-inspection process
c. Heijunka design improvement and optimization
d. poka-yoka permitting only proper plug insertion
D= correct
A 3-p
The normality of residuals for factor A indicate a uniform behavior around zero, what can be concluded from this fact?
a. There is something wrong with the model. Go back to the planning stage
b. Normality of the residuals has been demonstrated by the uni
The normality of residuals for factor A indicate a uniform behavior around zero, what can be concluded from this fact?
a. There is something wrong with the model. Go back to the planning stage
b. Normality of the residuals has been demonstrated by the uni
There are large number of potential human errors. What are the possible countermeasures for inexperience?
There are large number of potential human errors. What are the possible countermeasures for inexperience?
1) visual aid
2) work instruction s
3) work standardization
4) skill building
Based on the large number of variables under study, an engineer is considering a fractional factorial instead of a full factorial to analyze a process. Apart from the possibility of studying a large number of factors with relatively few experiments, what
Based on the large number of variables under study, an engineer is considering a fractional factorial instead of a full factorial to analyze a process. Apart from the possibility of studying a large number of factors with relatively few experiments, what
Almost in every definition of the standard work, one would find some combination of ?
Almost in every definition of the standard work, one would find some combination of ?
Answer = materials, man (workers) , and machinery
The tool/ techniques most widely used by a number of automotive suppliers to control material flow is called ??
The tool/ techniques most widely used by a number of automotive suppliers to control material flow is called ??
Kanban
After a screening experiment , all significant factor happen to be qualitative. A decision to run some intermediate values will result in :
a. nothing, it is not possible to optimize qualitative variables
b. discovery of the optimum combination qualitativ
After a screening experiment , all significant factor happen to be qualitative. A decision to run some intermediate values will result in :
a. nothing, it is not possible to optimize qualitative variables
b. discovery of the optimum combination qualitativ
Most fire hydrants in U.S. have a pentagon shaped head on the valve stem. Primary reason is that the head is not a square or pentagon is
A. to encourage the sale of the specialize wrenches for operation
B. Mistake proofing so only proper authorities can t
Most fire hydrants in U.S. have a pentagon shaped head on the valve stem. Primary reason is that the head is not a square or pentagon is
A. to encourage the sale of the specialize wrenches for operation
B. Mistake proofing so only proper authorities can t
American visitors to an aluminum plant in Japan were given white gloves to wear. What category of 5S is this an example of?
a. Sort
b. Scrub
c. Straighten
d. Standardize
American visitors to an aluminum plant in Japan were given white gloves to wear. What category of 5S is this an example of?
a. Sort
b. Scrub
c. Straighten
d. Standardize
B= correct--white rage inspection
Which of the following DOE strategies most resembles the Kaizen philosophy?
a. Response surface
b. Mixture designs
c. EVOP
d. One factor at a time analysis
Which of the following DOE strategies most resembles the Kaizen philosophy?
a. Response surface
b. Mixture designs
c. EVOP
d. One factor at a time analysis
C= correct
All 4 can be said to follow Kaizen. But EVOP is the only one that is a DOE strategy that
When describing a process being considered for cycle time reduction, the existing process flows are known as?
a. Key operation points (KOPS)
b. Dynamic Pull chart
c. Current state map
d. Activity network diagram
When describing a process being considered for cycle time reduction, the existing process flows are known as?
Current State Map
To state that a model in an experimental design is fixed indicates that???
To state that a model in an experimental design is fixed indicates that???
The levels used for each factor are the only ones of interest.
So a balanced design is then considered at only those levels. Based upon analysis, factors may then be adjusted to ot
Technique used to discover the most probable important factors in an experimental trial is called ?
Technique used to discover the most probable important factors in an experimental trial is called ?
Screening Experiment
This type of design tends to separate important from unimportant factors.
Which of the following is true in regards to blocking?
a. A block is a dummy factor which doesn't interact with real factors
b. A blocking factor has 2 levels
c. The experiment is a subdivision of the block
d. Blocks permit full randomization of runs
Which of the following is true in regards to blocking?
a. A block is a dummy factor which doesn't interact with real factors
b. A blocking factor has 2 levels
c. The experiment is a subdivision of the block
d. Blocks permit full randomization of runs
A= c
An organization is considering a kaizen blitz event fro improving the system software functionality by replacing the network server and implementing a new software program. Which of the following is the best response?
a. this is an ideal application becau
An organization is considering a kaizen blitz event fro improving the system software functionality by replacing the network server and implementing a new software program. Which of the following is the best response?
a. this is an ideal application becau
What type of data will a value stream provide?
What type of data will a value stream provide?
Changeover and cycle times and work-in-progress inventory
What process controls the tempo of the value stream?
What process controls the tempo of the value stream?
The pacemaker process.
Tempo of the manufacturing stream is controlled by pacemaker process and can be improved
The advantage of using the modern DOE, rather than the classical, is that: .....?
The advantage of using the modern DOE, rather than the classical, is that: .....?
Fewer terms and measurements are needed for valid and useful information.
The key to this question is the word classical., which means varying one factor at a time while hol
In a full factorial experiment with 4 factors and 3 levels, how many trials are required?
In a full factorial experiment with 4 factors and 3 levels, how many trials are required?
Answer= 81
No. of required trials = (#of levels) ^ (No. of factors)
3 ^4 =81
What tool is used to complement Fish-bone diagram?
What tool is used to complement Fish-bone diagram?
Brainstorming
Cause and effect diagram can be used to solve problems diagnosed via:
1) scatter diagram
2) Force field analysis
3) Pareto diagram
What is the basic statistical principle of EVOP?
What is the basic statistical principle of EVOP?
The ability to recognize small differences through large sample sizes
In Placket- Burman geometric designs, one would expect:
a. that each interaction effect is confounded with 2 main effects
b. that each interaction effect would not be confounded
c. that only pure main effects will be determined
d. that each interaction ef
In Placket- Burman geometric designs, one would expect:
a. that each interaction effect is confounded with 2 main effects
b. that each interaction effect would not be confounded
c. that only pure main effects will be determined
d. that each interaction ef
If an operator is presented with a tray containing all parts to be used in product assembly, what does the tray represent?
If an operator is presented with a tray containing all parts to be used in product assembly, what does the tray represent?
Visual Checklist
When selecting and scaling the process input variables for an experiment, which of the following is a desirable approach?
a. include as many factors as possible
b. set factor levels at extreme levels
c. combine process measurement responses when possible
When selecting and scaling the process input variables for an experiment, which of the following is a desirable approach?
a. include as many factors as possible
b. set factor levels at extreme levels
c. combine process measurement responses when possible
A fractional factorial experiment resulted in the main effects and two factor interactions effects being confounded. The confounding can be resolved how??
A fractional factorial experiment resulted in the main effects and two factor interactions effects being confounded. The confounding can be resolved how??
Answer: Run full factorial experiment with the same factors
A resolution III experiment is a fractio
Identify the assumption that is made when conducting an experiment:
a. that the measurement system is capable for all included responses.
b. that the selected factors are the only ones of importance.
c. that the process changes radically during the durati
Identify the assumption that is made when conducting an experiment:
a. that the measurement system is capable for all included responses.
b. that the selected factors are the only ones of importance.
c. that the process changes radically during the durati
What is the downside of adopting mistake proofing in the work place?
What is the downside of adopting mistake proofing in the work place?
In some cases, technical or engineering assistance may be needed especially if the remedies are out of control and capability of floor employees
Which of the following statements is true about Latin Square design?
a. minimizes the chance of factor confounding
b. does not allow for the effects of interaction in design
c. eliminates the need to ensure that the effects of interaction are additive
d.
Which of the following statements is true about Latin Square design?
a. minimizes the chance of factor confounding
b. does not allow for the effects of interaction in design
c. eliminates the need to ensure that the effects of interaction are additive
d.
At what stage in the 5S program would visual controls be employed?
At what stage in the 5S program would visual controls be employed?
Step 4: Standardize
What is the iterative approach to DOE?
What is the iterative approach to DOE?
Use of sequential expermentation---> produces more satisfactory results that "one big experiment
A value stream map that describes the process after lean principles have been applied is called........???
A value stream map that describes the process after lean principles have been applied is called........???
Future State Map
As a good experimenter, you have built a predictive model of the experimental data. The differences between the actual response data and the model data are called???
As a good experimenter, you have built a predictive model of the experimental data. The differences between the actual response data and the model data are called???
Residuals
Look up the definitions for:
Nested experiment, efficeincy of estimators
Hearing aids and eye glasses are example of:
a. Value stream mapping
b. Kanban
c. Poka-yoke
d. Kaizen
Hearing aids and eye glasses are example of:
a. Value stream mapping
b. Kanban
c. Poka-yoke
d. Kaizen
C=correct
A designed experiment of 3 factors (A, B, & C) at 2 levels was conducted. The 8 runs were analyzed, suggesting that one actor A showed significant improvement. the plan manager stated that no additional runs are needed. The best response:
A designed experiment of 3 factors (A, B, & C) at 2 levels was conducted. The 8 runs were analyzed, suggesting that one actor A showed significant improvement. the plan manager stated that no additional runs are needed. The best response:
Additional repli
Takt time takes on a great importance in:
a. Fishbone diagrams
b. 5S housekeeping organization
c. Poke-Yoke
d. Continuous flow manufacturing
Takt time takes on a great importance in:
a. Fishbone diagrams
b. 5S housekeeping organization
c. Poke-Yoke
d. Continuous flow manufacturing
D= correct
Assuming no interactions, the main effects of analysis of one-half factional factorial experiment compared with a comparable full factorial experiment, produces which outcome:
a. Both results are approximately the same
b. only full factorial is accurate
c
Assuming no interactions, the main effects of analysis of one-half factional factorial experiment compared with a comparable full factorial experiment, produces which outcome:
a. Both results are approximately the same
b. only full factorial is accurate
c
A six sigma project has progressed ot the point that a control plan is required. Control plan activities can be considered closed after which of the following?
a. process owner is named for the control plan
b. responsible engineer is designated
c. cross f
A six sigma project has progressed ot the point that a control plan is required. Control plan activities can be considered closed after which of the following?
a. process owner is named for the control plan
b. responsible engineer is designated
c. cross f
Basic objective of visual factory technique is?
Basic objective of visual factory technique is?
enable everyone to maintain contact with the workplace. ---
Visual factory technique make problems visible
Tool boards, jidohka devices, and red-lights all combine to:
a. make problems visible
b. prevent defective products
c. maintain management control
d. display targets for improvement
Tool boards, jidohka devices, and red-lights all combine to:
a. make problems visible
b. prevent defective products
c. maintain management control
d. display targets for improvement
A= correct.
Tool boards, jidohka devices, and red-lights= examples of vis
TPM in relation to lean enterprise system means what?
TPM in relation to lean enterprise system means what?
Total productive maintenance---- to maximize equipment effectiveness.
What is a control chart used for?
What is a control chart used for?
Detect non-random variation in the process.
The most common subgrouping scheme for X-bar -R-control charts to separate the variation:
a. within stream verse stream-to-stream
b. within time verses time - to - time
c. within piece verse piece-to-piece
d. inherent process verses error of measurement
The most common subgrouping scheme for X-bar -R-control charts to separate the variation:
a. within stream verse stream-to-stream
b. within time verses time - to - time
c. within piece verse piece-to-piece
d. inherent process verses error of measurement
B
Since many variables are important in control charting, what is the risk of having an operator plot a large number of characteristics?
Since many variables are important in control charting, what is the risk of having an operator plot a large number of characteristics?
Distraction from the actual process itself.
It's unlikely that CTQ characteristic will be overlooked. Control charting a
The visual factor would be supported to the greatest extent by:
a. Muda and gemba
b. Kanban and 5S
c. Gemba and Kanban
d. 5S and muda
The visual factor would be supported to the greatest extent by:
a. Muda and gemba
b. Kanban and 5S
c. Gemba and Kanban
d. 5S and muda
B= correct
Parts of 5S (color coding, outlines, and markings) support the visual factory.
What is jidhoka?
What is jidhoka?
A device that stops the machine whenever a defective is produced
What is the importance of the reaction plan in a control plan?
What is the importance of the reaction plan in a control plan?
It describes what will happen if a key variable goes out of control.
The actions in a reaction play should be the responsiblity of the people closest to the process
A process is in control with p-bar = 0.10 and n=100. The 3 sigma limits of the np control chart are ??
A process is in control with p-bar = 0.10 and n=100. The 3 sigma limits of the np control chart are ??
Answer is 1 and 19
UCL/ LCL = (n
p-bar) +/- 3
{square root of (n*p-bar (1-p-bar)}
UCL = (0.1
100) +/- 3
{square root of (100 *0.1 (1-0.1)}
= (10) +/- 3
An X-bar-R chart has been in control for some time. If the range suddenly and significantly increases, what happens to the mean?
An X-bar-R chart has been in control for some time. If the range suddenly and significantly increases, what happens to the mean?
Answer= Mean occasionally show out of control of either limit
If the range significantly increases, the more spread of the ind
An X-bar-R chart has been in control for long time. Points for the last 50 samples are very near the center line on the chart. In fact, they are all within one sigma of the center line. This indicates what?
a. desirable situation
b. undesirable situation
An X-bar-R chart has been in control for long time. Points for the last 50 samples are very near the center line on the chart. In fact, they are all within one sigma of the center line. This indicates what?
a. desirable situation
b. undesirable situation
An X-bar control chart is based on a sample size of 4. What happens if an operator mistakenly plots the value of the single observation on the control chart?
a. will not cause any mis-judgments if the process is in control.
b. will always be plotted near
An X-bar control chart is based on a sample size of 4. What happens if an operator mistakenly plots the value of the single observation on the control chart?
a. will not cause any misjudgments if the process is in control.
b. will always be plotted near t
While plotting a control chart, it is noted that two of the last 3 points are than 2 sigma, four out of the last points are greater than 1 sigma, and 8 successive points are on one sideof the center lime.
What should one do?
a. stop the process immediatel
While plotting a control chart, it is noted that two of the last 3 points are than 2 sigma, four out of the last points are greater than 1 sigma, and 8 successive points are on one sideof the center lime.
What should one do?
a. stop the process immediatel
Who has ultimate responsiblity initially for the control plan?
Who has ultimate responsiblity initially for the control plan?
Green belt
Find the control limt for S-chart, when N= 10, Mean = 40, Sigma = 7, and process is in control.
Find the control limit for S-chart, when N= 10, Mean = 40, Sigma = 7, and process is in control.
Answer= 12.0
When N= 10, B4= 1.72
UCL - (B4) (S-bar) = 1.72 * 7 = 12.04
If a process is out of control, the theoretical probability that a single point on the X-bar chart will fall between one sigma and the UCL:
a. 0.2220
b. 0.1587
c. Unknown
d. 0.3413
If a process is out of control, the theoretical probability that a single point on the X-bar chart will fall between one sigma and the UCL:
a. 0.2220
b. 0.1587
c. Unknown
d. 0.3413
C= correct.
Tricky question. "out of control" = key phrase
If the process
What control chart is recommended to plot defective using a fixed sample size?
What control chart is recommended to plot defective using a fixed sample size?
np chart
**p-chart uses a variable number of samples but np uses a fixed number of sample
On X-bar chart, many plot points are noted in zone B, some in zone C, and few in zone A, what could be occurring the process?
a. Trends or over corrections
b. Stratification
c. Mixtures or systematic variation
d. Improper calculation of the control limits
On X-bar chart, many plot points are noted in zone B, some in zone C, and few in zone A, what could be occurring the process?
a. Trends or over corrections
b. Stratification
c. Mixtures or systematic variation
d. Improper calculation of the control limits
Effective control charts subgrouping includes which of the following actions?
a. Group product so that the subgroups are heterogeneous as possible
b. Group product produced over a long period of time
c. Group product to achieve a minimum opportunity for v
Effective control charts subgrouping includes which of the following actions?
a. Group product so that the subgroups are heterogeneous as possible
b. Group product produced over a long period of time
c. Group product to achieve a minimum opportunity for v
In Japanese based companies using TPM ....the goal for equipment break down losses is ________minutes
In Japanese based companies using TPM ....the goal for equipment break down losses is ________minutes
Zero minutes
When designing TPM, why would BITE (built-in test equipment) be of advantage?
When designing TPM, why would BITE (built-in test equipment) be of advantage?
In fault isolation.
A stamping press makes 4 parts at a time. To set up control charting for this process, the best rational subgrouping should be to:
a. separate control charts for each cavity, using 4 sequential part
b. use one control chart for the press, using 4 parts fr
A stamping press makes 4 parts at a time. To set up control charting for this process, the best rational subgrouping should be to:
a. separate control charts for each cavity, using 4 sequential part
b. use one control chart for the press, using 4 parts fr
Implementation of a control plan in the painting department was so successful that a master black belt wants you to implement the same control plan in the final assembly line. What changes should be made before implementing the necessary control plan?
a.
Implementation of a control plan in the painting department was so successful that a master black belt wants you to implement the same control plan in the final assembly line. What changes should be made before implementing the necessary control plan?
a.
A p-chart has been plotted for some time. Recently steps have been made to substaintially improve the process. One would not be surprised ot find that : ?/
A p-chart has been plotted for some time. Recently steps have been made to substaintially improve the process. One would not be surprised ot find that : ?/
Larer sample size mus be taken
Hypothetical situation. Ofent with an improved process, a lartger sa
In Japanese and American system, the flow of material is control by ......??
In Japanese and American system, the flow of material is control by ......??
Kanban cards
Most experts content that the most neglected phase of the DMAIC improvement process is .....?
Most experts content that the most neglected phase of the DMAIC improvement process is .....?
Control phase
Most difficult type of variability to reduce via control charting and/or other techniques is _______?
Most difficult type of variability to reduce via control charting and/or other techniques is _______?
Inherent error of measuremnt
After implementation of TPM, wha tis the long-term objective?
After implementation of TPM, wha tis the long-term objective?
Perfection
How many individual values are considered sufficeint to accurately calculate the upper and lower control limits of X-bar-R control charts.
How many individual values are considered sufficeint to accurately calculate the upper and lower control limits of X-bar-R control charts.
100 data values
Why should an X-MR chart be used?
Why should an X-MR chart be used?
For destructive testing process
On an automotie secior, the APQP identifies what control plan for the early development states of the product?
On an automotie secior, the APQP identifies what control plan for the early development states of the product?
Prototype
Prelauch comes next , followed by the production phase.
Simplificiton of paperwork, minimazation of WIP, and reduction of finished goods inventories, can be achieved utilizing .....?
Simplificiton of paperwork, minimazation of WIP, and reduction of finished goods inventories, can be achieved utilizing .....?
Kanban pull system
What charting charting process uses data for multiple data for multiple plot point?
What charting charting process uses data for multiple data for multiple plot point?
MX bar- MR charts
Compare with np charts, run charts, Xbar-R charts.
What control chart pattern best represents an in cntrol process?
What control chart pattern best represents an in o
rcntrol process?
Random distribution of points on either side fo the cener line.