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What is the primary goal of Six Sigma?

• AIncrease production speed by 50%
• BReduce process variation and defects to achieve near-perfect quality
• CEliminate all employees in the quality department
• DCreate more paperwork and documentation

What does DMAIC stand for in Six Sigma?

• ADesign, Measure, Analyze, Improve, Control
• BDefine, Measure, Analyze, Improve, Control
• CDevelop, Monitor, Assess, Integrate, Complete
• DDocument, Manage, Audit, Implement, Check

In a Six Sigma organization, what is the primary role of an Executive?

• ATo perform statistical analysis on project data
• BTo provide strategic direction, resources, and remove barriers
• CTo lead daily project team meetings
• DTo manually inspect all products before shipment

What is the key difference between Lean and Six Sigma?

• ALean focuses on speed and waste reduction while Six Sigma focuses on variation reduction
• BLean is only for manufacturing while Six Sigma is only for service industries
• CLean requires Black Belts while Six Sigma requires only Green Belts
• DThere is no difference; they are identical methodologies

What is Design for Six Sigma (DFSS) used for?

• AImproving existing processes with known problems
• BCreating new processes or products that meet customer requirements from the start
• CTraining employees on basic quality tools
• DDocumenting historical process performance data

A process currently operates at 4.5 sigma level (short-term). Using the standard 1.5 sigma shift, what is the approximate long-term defect rate?

• A3.4 defects per million opportunities
• B1,350 defects per million opportunities
• C66,807 defects per million opportunities
• D233 defects per million opportunities

What is a Project Charter in Six Sigma?

• AA document that formally authorizes the existence of a project
• BA tool for measuring process capability
• CA statistical software license agreement
• DAn employee vacation schedule

What does CTQ stand for in Six Sigma?

• ACritical to Quality
• BCost Time Quantity
• CCentral Testing Queue
• DComplete Total Quality

What is the Voice of the Customer (VOC)?

• AA monthly management meeting
• BThe process of capturing customer requirements, expectations, and feedback
• CA quality control inspection station
• DA type of statistical chart

In a SIPOC diagram, what does the "S" represent?

• AStrategy
• BSuppliers
• CStandards
• DSpecifications

What is the purpose of a Stakeholder Analysis?

• ATo replace the project team
• BTo identify individuals or groups affected by the project and understand their influence…
• CTo calculate process capability indices
• DTo design control charts

Which tool is commonly used to translate Voice of Customer into Critical to Quality requirements?

• AGantt chart
• BQFD (Quality Function Deployment) or House of Quality
• CPareto chart
• DHistogram

What is scope creep in a Six Sigma project?

• AThe gradual expansion of project scope without corresponding adjustments to time, cost, a…
• BA type of insect found in manufacturing facilities
• CThe process of hiring additional team members
• DA method for measuring small variations

What is the primary output of the Define phase?

• AStatistical process control charts
• BA clear problem statement, project scope, and approved project charter
• CRoot cause analysis results
• DOptimized process parameters

During a project selection process, which financial metric is calculated as (Benefits - Costs) / Costs and represents the return per dollar invested?

• ANet Present Value (NPV)
• BReturn on Investment (ROI)
• CInternal Rate of Return (IRR)
• DPayback Period

A team is defining a project to reduce customer complaints about late deliveries. Which element should NOT be included in the problem statement?

• AThe specific metric being affected (delivery time)
• BThe magnitude of the problem (frequency/severity)
• CThe proposed solution (implement a new scheduling system)
• DThe timeframe when the problem occurs

What is the purpose of a Data Collection Plan?

• ATo store historical data for future reference
• BTo define what data to collect, how to collect it, who will collect it, and when
• CTo create a backup of all computer files
• DTo design marketing materials

What does Gage R&R study assess?

• AEmployee satisfaction ratings
• BThe variation in measurement systems from equipment and operators
• CProduction line speed
• DCustomer return rates

What is the mean of the following data set: 10, 15, 20, 25, 30?

• A15
• B20
• C25
• D30

What is process capability ratio (Cp)?

• AThe ratio of actual performance to budgeted performance
• BThe ratio of specification width to process width (USL - LSL) / 6σ
• CThe number of employees per process
• DThe ratio of defects to total units

What is the difference between Cp and Cpk?

• AThere is no difference; they are the same
• BCp measures potential capability; Cpk measures actual capability considering centering
• CCp is for manufacturing; Cpk is for service industries
• DCp measures cost; Cpk measures quality

A process has USL = 20, LSL = 10, mean = 14, and standard deviation = 1. What is Cpk?

• A1.0
• B1.33
• C1.67
• D2.0

In measurement system analysis, what does reproducibility refer to?

• AVariation when the same operator measures the same part multiple times
• BVariation between measurements taken by different operators using the same gage
• CThe ability to reproduce a product exactly
• DThe consistency of raw material quality

What is the standard deviation?

• AThe average of all data points
• BA measure of the amount of variation or dispersion in a set of values
• CThe middle value in an ordered data set
• DThe most frequently occurring value

A measurement system study shows %Study Variation = 25%, %Tolerance = 18%, and %Process = 30%. How would you classify this measurement system?

• AAcceptable - no action needed
• BMarginally acceptable - may need improvement depending on application
• CUnacceptable - measurement system needs improvement
• DExcellent - better than required

Given a normally distributed process with mean = 50, standard deviation = 2, what percentage of data falls between 46 and 54?

• A68%
• B95%
• C99.7%
• D50%

What is a Pareto Chart used for?

• ATo show the relationship between two variables
• BTo identify the vital few causes that contribute to most of the problems
• CTo monitor process variation over time
• DTo calculate process capability

What is the primary purpose of Root Cause Analysis?

• ATo assign blame to specific employees
• BTo identify the underlying causes of problems or defects
• CTo create a project schedule
• DTo calculate financial returns

What is the 5 Whys technique?

• AA method for asking 5 customers about their satisfaction
• BAn iterative questioning technique to explore cause-and-effect relationships
• CA statistical test for comparing 5 samples
• DA way to assign 5 team members to a project

In a Fishbone (Ishikawa) diagram, which category is NOT one of the traditional 6Ms?

• AManpower (People)
• BMachine
• CMoney
• DMethod

What does a p-value less than 0.05 typically indicate in hypothesis testing?

• AThe null hypothesis should be rejected
• BThe null hypothesis is definitely true
• CThe sample size was too small
• DThe data is normally distributed

What is the null hypothesis (H0) in hypothesis testing?

• AThe hypothesis that there is a significant difference or effect
• BThe hypothesis of no difference or no effect that we test against
• CThe hypothesis proposed by the project team
• DThe final conclusion of the analysis

What type of correlation is indicated by a correlation coefficient (r) of -0.85?

• AStrong positive correlation
• BStrong negative correlation
• CWeak positive correlation
• DNo correlation

A team suspects that temperature affects product quality. They collect data and perform a 2-sample t-test comparing quality at 70°F vs 80°F. The p-value is 0.03. What conclusion should be drawn?

• ATemperature definitely causes quality changes
• BThere is statistically significant evidence that the mean quality differs between the two…
• CThere is no difference in quality between temperatures
• DThe sample size needs to be increased

In regression analysis, what does the coefficient of determination (R-squared) represent?

• AThe slope of the regression line
• BThe proportion of variance in the dependent variable explained by the independent variabl…
• CThe correlation between two variables
• DThe standard error of the estimate

What is the purpose of a Pilot Run in the Improve phase?

• ATo train all employees on new procedures
• BTo test improvements on a small scale before full implementation
• CTo calculate financial savings
• DTo create marketing materials

What is Error Proofing (Poka-Yoke)?

• AA method for catching errors after they occur
• BDesigning processes to prevent errors or make them immediately obvious
• CA technique for blaming employees who make mistakes
• DA statistical tool for analyzing defects