40-Hr Lean Six Sigma Green Belt Exam Please enter your name as you would like it to appear on your Lean Six Sigma Green Belt Certificate. Your email address: Your name: Company name: Begin Your Exam 1. Which statement best captures the definition of non-value-adding?We implemented a proposal to increase revenue, but it didn’t work.This staff member consistently receives poor performance evaluations.There is a feasible future state in which we could deliver this product or service without having to perform this activity.Our top management team is incapable of making good decisions. 2. Workers are doing too much turning, bending over, and walking from one place to another. Which letters of DOWNTIME best capture problems like these?O and TO and IT and IT and M 3. Which improvement strategy will have the greater impact?Optimizing the value-adding portions of the workflow.Reducing the non-value-adding portions of the workflow.Firing employees with consistently poor performance.Promoting employees with consistently good performance. 4. What is a value stream? A live video you can watch on the Internet. A steady flow of orders for your products or services. A department specializing in one particular step in a manufacturing or service process. The set and sequence of all activities required to produce and/or deliver a specified family of products or services to customers. 5. A workflow consists of three main steps. The yields for each of these steps are 99%, 98%, and 97%. Which of the following values is closest to the overall quality level (rolled throughput yield)?99%98%97%94% 6. Which of these following statements is typically NOT true? Your customers are more concerned with your DPMO than your DPPM. Your customers are more concerned with your DPPM than your DPMO.DPMO will signal process deterioration sooner than DPPM. DPMO responds more rapidly to process improvements than DPPM. 7. A company wants to use DPMO to track product quality. Which of the following issues would make that impossible?Their customers are not familiar with DPMO. Their products do not have a finite number of identifiable opportunities for defects.Calculating DPMO is more difficult than calculating DPPM. DPMO requires more detailed data collection than DPPM. 8. Which of the following is NOT a reason to combine Lean and Six Sigma as a single improvement infrastructure?They have common belief systems. They have common strategies.They are different names for the same thing.They have complementary tool sets. 9. Which of the following is NOT an essential element of LSS?Signs posted throughout the company declaring the company’s commitment to LSS. A culture of continuous improvement.Teamwork within and across departments.Front line workers participating in LSS projects. 10. Which of the following is NOT a deliverable of the Measure phase of DMAIC? Observe and map the current state.Collect data on the current state.Calculate project metrics for the current state. Determine root causes. 11. Which of the following is NOT a deliverable of the Improve phase of DMAIC?Monitor the future state after it is implemented. Develop the future state. Review the proposed future state with stakeholders. Pilot the future state. 12. Which of the following is NOT a deliverable of the Control phase of DMAIC? Implement the future state within the project scope.Implement the future state in out-of-scope replication areas. Develop a control plan.Monitor the future state after it is implemented. 13. Which project is MOST likely to benefit from Lean concepts and methods?Reduce machine setup time. Reduce cosmetic defects.Reduce dimensional nonconformancePurchase a new machine. 14. Which of the following is NOT a deliverable of SIPOC?Identifying the main steps of the in-scope workflow. Identifying the outputs and customers of the in-scope workflow. Identifying the inputs and suppliers of the in-scope workflow.Identifying the goals of the project with respect to the in-scope workflow. 15. Which of the following is NOT a purpose of observing the current state?Identifying the location and types of waste.Punishing people for making mistakes.Identifying possible causes of problems.Identifying opportunities for improvement. 16. Basic process mapping (flowcharting) is MOST useful for: Showing the sequence of activities and decision points in the in-scope workflow.Showing WIP for the main steps in the in-scope workflow.Showing cycle times for the main steps in the in-scope workflow.Identifying responsibility for each step in the in-scope workflow. 17. Which of these cycle times represents the fastest rate of production?1 minute.2 minutes.3 minutes.4 minutes. 18. Suppose a manufacturing process has a cycle time of 1.5 minutes. How many parts are produced each hour?10203040 19. The purpose of value stream and process mapping is to:Show what should happen.Show what actually happens.Show what we think happens.Document the process for ISO auditors. 20. Value stream mapping is MOST useful for:Showing hand-offs in the in-scope workflow. Showing do-overs in the in-scope workflow.Identifying responsibility for each step in the in-scope workflow.Showing WIP and cycle times for the main steps in the in-scope workflow. 21. The average WIP in a workflow is 50 items. 5 items are completed each day. What is the average lead time?250 days5 days10 days0.2 days 22. We want to do an analysis to determine whether getting a customer order from a quote is more likely or less likely depending on which account manager submitted the request for quote to the customer, which business unit created the quote, and the turnaround time. What is the Y variable for this analysis?Which account managerTurnaround timeWhether or not we got a customer orderWhich business unit 23. We want to do another analysis involving the four variables below. Which of the following choices would be the Y variable, i.e., the one that could be dependent on the other three X variables?Whether or not review by Legal was required Whether or not the quote was submitted on time to the customer Whether or not review by Finance was requiredWhether or not review by Service was required 24. Suppose that a population of interest can be divided into several homogeneous sub-populations of equal size. Which sample will be most representative of the population?A random sample from the sub-population for which the data can be obtained most quickly. A random sample from the sub-population for which the data can be obtained most inexpensively.Random samples of the same size from each sub-population. A random sample from the whole population. 25. Which of these statements about random sampling is always true?The sample data looks random when you plot it. A random number generator should be used to select the items in the sample.The items in the sample are equally spaced in time or location.It gives a smaller margin of error than other sampling methods. 26. We want to collect data to estimate a population mean. We think the sample standard deviation will be about 20, and we want a margin of error equal to 5. Like almost everyone else who does this sort of thing, we will use the 95% confidence level. What is the required sample size?64844424 27. We want to collect data to estimate a population percent defective. Our guess for the percent defective is 20. We want an upper margin of error equal to 5 percentage points, equivalent to an upper bound of 25 on the population percent defective. We will use the 95% confidence level. What is the required sample size?613811415 217 28. Which of these variables is a quantitative measurement?The order entry time Whether or not an order is completeWhether or not an order is accurateWho enters the order 29. Which of these variables is a categorical classification?The order quantityThe product that is being orderedThe dollar value of an orderThe order processing time 30. We have a quantitative variable that follows a Normal distribution with mean 50 and standard deviation 5. What percentage of future observations will exceed 60?5.002.281.9697.72 31. Which of the following statistics is a measure of process variation?Standard deviationAverageSumMinimum 32. Suppose we have a quantitative measurement system for which standards are NOT available. What could we determine in a measurement system analysis for this case?The bias of the measurement system.The percentage of good items that are failed. The standard deviation attributable to the measurement system.The percentage of bad items that are passed. 33. Suppose we have a quantitative MSA involving 5 items, 9 appraisers, and 2 sessions. What is the number of degrees of freedom for repeatability?45859040 34. For the MSA in the previous question, what is the number of degrees for freedom for reproducibility?90854540 35. Which of the following is NOT a result of measurement system variation?Making observed variation look worse than it really is. Making observed variation look better than it really is.Passing bad items.Failing good items. 36. Which Excel tool is needed for a quantitative measurement system analysis involving multiple parts and multiple appraisers?Data Analysis → Anova: Single Factor.Data Analysis → Descriptive Statistics.Data Analysis → Regression.Data Analysis → Anova: Two-Factor with Replication 37. We have a quantitative measurement system for which there are 10 appraisers. Which of the following is the best design for a measurement system analysis?10 items, 3 appraisers, 3 sessions. 5 items, 9 appraisers, 2 sessions.9 items, 9 appraisers, 1 session1 item, 10 appraisers, 9 sessions. 38. Suppose we have a categorical measurement system for which standards ARE available. What could we determine in a measurement system analysis for this case?The repeatability and reproducibility of the measurement system. The bias of the measurement system. The percent agreement with standard. The measurement error (3σms) of the measurement system. 39. Suppose we have a categorical measurement system for which standards ARE available. Which quantity will we NOT be able to determine in a measurement system analysis?The percentage of tolerance consumed by measurement system variation.The percentage of inspections of good items that give an incorrect answer (i.e.,fail). The percentage of inspections of bad items that give an incorrect answer (i.e., pass).The overall percentage of inspections that give the correct answer. 40. Which of the following is NOT true about the process capability indices Cp and Cpk?The process must be in statistical control for the indices to be valid.Lower numbers are considered better for Cp and Cpk indices. The data used to calculate the indices should be representative of typical process variation. The indices quantify how well a process is able to meet customer requirements. 41. Which of the following is NOT true about Cp?Cp compares the 6σ (six-sigma) spread of the process to the width of the spec limits.The limitation of Cp is that it doesn’t take into account the process mean (aka average). When the spec limits are exactly at +3σ and -3σ from the mean, Cp = 1.0.When Cp = 1.0, the process is considered a Six Sigma process and “world class” capability. 42. For a process with Cp = 1.33 and Cpk= 0.9, which of the following is NOT true?The Tolerance Band (Upper Spec Limit – Lower Spec Limit) is wider than the 6σ (six-sigma) spread of the process. The process is considered to be “marginally capable.”Cpu and Cpl are not the same for this process.Centering this process would improve its capability. 43. Which question involves a comparison of populations?Does the future state pilot indicate a significant improvement over the current state?Does the future state pilot show that we have achieved our project objectives? What is the percent defective in the current state?Can we accurately estimate the number of sheets in a ream of paper based on its weight? 44. Which question involves correlating variables?Does the future state pilot indicate a significant improvement over the current state?Does the future state pilot show that we have achieved our project objectives? What is the percent defective in the current state?Can we accurately estimate the number of sheets in a ream of paper based on its weight? 45. Which chart type is recommended for showing the correlation between two quantitative variables?HistogramBox and WhiskerPieScatter 46. For a quantitative Y variable, what is the correct Excel tool for comparing populations?Data Analysis → Descriptive Statistics. Data Analysis → Anova: Single Factor.Data Analysis → Regression.Pivot table → chi square test. 47. Which is the correct Excel tool for correlating variables?Data Analysis → Descriptive Statistics. Data Analysis → ANOVA: Single Factor.Data Analysis → Regression.Pivot table → chi square test 48. The P value from a before-after comparison is 0.0375. What is the correct conclusion?There is very strong evidence that the processes are different.There is strong evidence that the processes are different.There is some evidence that the processes are different. There is no evidence that the processes are different. 49. The P value from a correlation analysis is 0.7350. What is the correct conclusion?There is very strong evidence that the two variables are correlated. There is strong evidence that the two variables are correlated.There is some evidence that the two variables are correlated.There is no evidence that the two variables are correlated. 50. What is the appropriate next step if a stratification analysis results in a P value of 0.7350?Identify worst practice and initiate disciplinary action.Identify best practice and make it the standard. Do not pursue this line of inquiry further; look for other stratification analyses that might lead to a root cause.Change some of the data values and run the analysis again. 51. What is the appropriate next step if a correlation analysis of X and Y variables results in a P value of 0.0375?Investigate ways to control the X variable within a desirable range.Find out who is responsible for the X variation and initiate disciplinary action.No follow-up is called for.Collect more data. 52. Which of these tools or techniques is NOT used in validating root causes or critical X variables?Correlation/Regression Multi-level Pareto ChartsMulti-votingANOVA 53. At the end of the Analyze Phase, to determine which root causes or critical X variables to address in the Improve Phase, the team must do which of the following?Cast votes for each root cause.Review all analyses completed and identify which have been validated as significant contributors to poor performance in the Y metric.Rank causes by frequency of occurrence, severity of impact on Y variables, and ability to detect when they occur.Write the causes on small pieces of paper, put them in a bowl, then randomly draw three to five of them. 54. Which of the following is NOT a source of improvement ideas?Obvious once the root cause is found. Best practices revealed by stratification analysis of current-state data.Best practices from Lean. SIPOC. 55. What is the recommended team process for prioritizing solution ideas?Cast votes for each idea.Write the ideas on small pieces of paper and put them in a bowl. Randomly draw one of them from the bowl. Repeat until the bowl is empty. Rank them by impact on root causes and feasibility metrics. Do an impact-feasibility analysis based on KPIs and feasibility metrics. 56. Which benefit is associated with larger batch sizes?Fewer changeovers. Shorter cycle time. Lower cost of waste.SIPOC.Less work in process. 57. Which statement correctly captures the meaning of pull system?Work is performed prior to actual demand from internal or external customers, on the basis of anticipated demand.A system of pulleys for safe retrieval of heavy containers stored on high shelves.Work is performed only in response to actual demand from internal or external customers.A way of moving equipment from one location to another. 58. A workflow consists of three consecutive operations A, B, and C, one operator per operation. The cycle time for Operation A is 10 minutes. The cycle time for Operation B is 15 minutes. The cycle time for Operation C is 5 minutes. What is the fastest possible cycle time of the workflow?5 minutes. 10 minutes.15 minutes30 minutes. 59. In the previous question, which is the better way to reduce the workflow’s cycle time?Add a second operator to operation A.Cross train the current A and B operators, have both of them do A + B.Add a second operator to operation B. Cross train the current B and C operators, have both of them do B + C. 60. Which of the following is NOT a purpose of FMEA in an LSS project?To identify and prioritize stakeholder concerns with the proposed future state. To take appropriate corrective actions prior to piloting the proposed future state.To strengthen the control plan for the proposed future state.To convince stakeholders that their concerns with the proposed future state are groundless. 61. The term severity in FMEA refers to the:Difficulty of filling out the FMEA form. Degree of impact a failure mode will have if it happens.Probability that a failure mode will happenDifficulty of knowing if a failure mode has happened. 62. The term occurrence in FMEA refers to the:Number of errors made in filling out the FMEA form.Degree of impact a failure mode will have if it happens. Probability that a failure mode will happen. Difficulty of knowing if a failure mode has happened. 63. The term detection in FMEA refers to the:Difficulty of finding errors made in filling out the FMEA form.Degree of impact a failure mode will have if it happens.Probability that a failure mode will happen.Difficulty of knowing if a failure mode has happened. 64. Which of the following is NOT good practice for piloting the future state?Scope should be limited. Only the core project team should be involved.Time period should be relatively short.Should be closely observed. 65. Which of the following is NOT true of the data collected while piloting the future state?Y variables must be the same as in the current state data. Measurement systems may or may not be the same as in the current state data.Project metrics must be the same as in the project charter.The sample size for the pilot must equal the sample size for the current state data. 66. Which of the following is NOT true of a Control Plan?It summarizes the plan to sustain gains from an LSS project. It is temporary.It outlines the methods used to monitor the future state process after the LSS project concludes. The in-scope process owner and participants should be involved in developing the control plan. 67. Which of the following is NOT a characteristic of assignable-cause variation?Is statistically predictable. Consists of mistakes, malfunctions, miscommunications, external factors, etc.Consists of relatively few large fluctuations.Causes of individual fluctuations can be determined. 68. Which of the following is NOT a characteristic of statistical control limits?They are an economic compromise between false alarms and missed signals.Are usually based on +/- three-sigma limits from the mean, calculated from pilot data in the case of an LSS project.They are equivalent to the specification limits for the parameter being charted. They provide an operational definition of the range of common-cause variation. 69. How is a response plan used in statistical control chart monitoring?It is used to disposition parts that don’t meet customer spec limits. It is used to assign blame for OOC (out of control) points. It is used by department managers to address personnel issues.It is used to diagnose assignable causes when they occur (i.e., the associated control chart is OOC), and to take corrective action to prevent future occurrences. 70. A control plan requires that every two hours, one part is sampled from an epoxy bonding process and a destructive shear strength test is performed, with the value (measured in units of pounds per square inch, psi) plotted on a control chart. What is the most appropriate control chart to use in this case?p chartX-bar and s chart (average and standard deviation) IX and MR chart (individual and moving range)X-bar and R chart (average and range) 71. A product characteristic has the following specification limits: USL = 8, LSL = 4. A sample of 5 parts per hour is taken and the average is plotted on an X-bar control chart with the following control limits: UCL = 7, CL = 5, LCL =3. For a sample with an average equal to 7.3, what is the appropriate response in this situation?Keep running the process.Initiate the control chart response plan.Scrap all parts in the sample.Tell the operator to be more careful. Loading...