LSS GB Exam TK - ETI Group

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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.

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 T

O and I

T and I

T and M

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.

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.

Kaizen events are sometimes used in LSS projects. Which of the following is NOT a characteristic of Kaizen Events?

They place more emphasis on “tribal knowledge” or “wisdom of the organization,” less emphasis on data analysis.

They address product/service defects &/or process issues for which the root causes are unknown.

They address problems for which causes and solutions are easy to identify.

They produce solutions posing little or no implementation risk.

Which of the following is NOT part of the preparation for a typical Kaizen Event?

Current state process maps completed.

Data collected, project metrics calculated, goals set.

Solutions to the problem have been developed.

Event logistics have been arranged.

Which of the following is a common pitfall of typical Kaizen Events?

Getting front line workers involved in identifying causes of problems.

Not putting a control plan in place to sustain the gains after the event.

Getting front line workers involved in developing solutions.

Having managers attend the project report-out.

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%

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.

10.

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.

11.

What is the primary responsibility of a LSS Champion?

Providing resources and removing organizational barriers for LSS project teams.

Leading LSS project teams

Analyzing data collected by LSS project teams.

Interviewing front line workers within the project scope.

12.

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.

13.

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.

14.

Which of these initiatives has the LEAST overlap with Lean Six Sigma?

Voice of the customer.

Succession planning

ISO 9001

Balanced scorecard.

15.

Which of the following is NOT an important Top Management role in LSS deployment?

Leading LSS project teams.

Defining Key Performance Indicators (KPIs).

Identifying candidate projects.

Prioritizing candidate projects.

16.

Which of the following is NOT a good reason to limit the number of LSS projects in process?

Results in manageable workloads for Green and Black Belts.

Results in reduced project cycle times.

Green and Black Belts who do not want to work on projects don’t have to.

Results in more rapid accrual of project benefits.

17.

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.

18.

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.

19.

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.

20.

Which of the following is NOT a recommended requirement for all LSS projects?

Clearly defined scope and boundaries.

Combination of process observation and data analysis.

Root causes identified and solutions implemented in a 3-5 day kaizen event.

Use of statistical monitoring to sustain gains.

21.

Which of the following is NOT a LSS project?

Reduce machine setup time.

Reduce cosmetic defects.

Reduce dimensional nonconformance.

Purchase a new machine.

22.

Which project is MOST likely to benefit from Lean concepts and methods?

Reduce machine setup time.

Reduce cosmetic defects.

Reduce dimensional nonconformance

Purchase a new machine.

23.

Which of these statements about cost-of-waste analysis is NOT true?

It contributes to project selection and scoping.

It is needed to establish project baselines.

It is needed to determine project benefits.

It is the same as cost-of-poor-quality analysis.

24.

What is the recommended team process for prioritizing a list of candidate LSS projects?

Cast votes for each project.

Do an impact-feasibility analysis based on KPIs and feasibility metrics.

Rank the projects by degree of relevance to the most recent crisis.

Use Failure Modes and Effects Analysis.

25.

Which of these elements does NOT belong in a project charter?

In-scope products, materials, services, and/or customers.

Boundaries of the in-scope workflow.

Discussion of particular stakeholders and how they feel about the project.

Statement of what the project metrics are.

26.

Which of these elements does NOT belong in a project charter?

A description of the solution that will be implemented.

An objective description of the problem the project will try to solve.

Team members, resources, and stakeholders.

Project milestones with anticipated completion dates.

27.

Which of the following is NOT an acceptable project metric? (RMA is a Return Material Authorization.)

The number of RMAs last year that took more than two days to process.

The average time to process an RMA.

The percentage of RMAs that have missing information.

The percentage of RMAs that contain incorrect information.

28.

You have quantitative measurements on N parts or transactions. Which of these statistics is NOT an acceptable project metric?

Average of the N measurements.

Percent of the N measurements that are smaller than a specified value.

Largest of the N measurements.

Percent of the N measurements that are larger than a specified value.

29.

A stakeholder is any person or organization who:

Is affected by the project and its outcome.

Is very supportive of the project.

Wishes the project would just go away.

Has no position relative to the project.

30.

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.

31.

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.

32.

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.

33.

Cross-functional (“swimlane”) process mapping is LEAST 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 cycle times for the main steps in the in-scope workflow.

34.

Which of these cycle times represents the fastest rate of production?

1 minute.

2 minutes.

3 minutes.

4 minutes.

35.

Suppose a manufacturing process has a cycle time of 1.5 minutes. How many parts are produced each hour?

36.

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.

37.

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.

38.

The average WIP in a workflow is 50 items. 5 items are completed each day. What is the average lead time?

250 days

5 days

10 days

0.2 days

39.

An organization wants to perform root cause analysis to determine whether getting a customer order from a quote is more likely or less likely depending on which of their account managers submits the quote to the customer, which business unit creates the quote, and the turnaround time for the quote, i.e., the elapsed time from when the customer’s request for quote (RFQ) was received by the organization until a quote response was sent to the customer. What is the Y variable for this analysis?

Which account manager

Turnaround time

Whether or not we got a customer order

Which business unit

40.

The organization wants to do additional root cause analysis for the quote process in the previous question, this time for a different Y variable and three different X variables, as listed below. Which of the following choices, (a, b, c, or d) is the Y variable in this case, 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 required

Whether or not review by Service was required

41.

Which of the following is NOT a description of the standard data matrix format?

Columns are fields, rows are records.

Columns are records, rows are fields.

It is the format required by Pivot Tables.

Each unique variable must appear in only one column.

42.

Which of these variables is a quantitative measurement?

The order entry time

Whether or not an order is complete

Whether or not an order is accurate

Who enters the order

43.

Which of these variables is a categorical classification?

The order quantity

The product that is being ordered

The dollar value of an order

The order processing time

44.

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?

5.00

2.28

1.96

97.72

45.

Which of the following statistics is a measure of process variation?

Standard deviation

Average

Sum

Minimum

46.

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.

47.

Suppose we have a quantitative MSA involving 5 items, 9 appraisers, and 2 sessions. What is the number of degrees of freedom for repeatability?

48.

For the MSA in the previous question, what is the number of degrees of freedom for reproducibility?

49.

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.

50.

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

51.

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 session

1 item, 10 appraisers, 9 sessions.

52.

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 (3σ_ms) of the measurement system.

53.

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.

54.

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.

55.

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.

56.

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?

57.

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?

613

811

415

217

58.

Using the file proto builds, imagine that this data has been collected from the Current State process. Find the overall percent failing in the data. Which of the following is the correct percentage?

31%

77%

69%

23%

59.

A Pareto chart is used to:

Identify the highest priority problems or problem areas.

Brainstorm a large number of ideas.

Determine whether two variables are correlated .

Calculate a required sample size.

60.

If we have failure reasons in a column in Excel, what is the recommended way to determine the number of occurrences for each failure reason?

Sort the failure reason column alphabetically, then manually count how many times each failure reason occurs

Use a Pivot Table

Use Data Analysis → Descriptive Statistics

Use the function =AVERAGE

61.

In a binding operation, the average numbers of defects per book are given (by category) as follows: 32.7 (Emulsion), 65.4 (Folds), 43.6 (Grease), 54.5 (Sewing). In what order, from left to right, would the categories be listed on a Pareto chart?

Emulsion, Grease, Sewing, Folds

Folds, Sewing, Grease, Emulsion

Emulsion, Sewing, Grease, Folds

Sewing, Grease, Emulsion, Folds

62.

The standard elements of a basic statistical summary for quantitative data are:

Mean, standard deviation, skewness, kurtosis, sample size

Mean, standard error, skewness, kurtosis, sample size

Mean, standard deviation, minimum value, maximum value, sample size

Mean, standard error, minimum value, maximum value, sample size

63.

What is the recommended way (in Excel) to produce a basic statistical summary for quantitative data?

Data Analysis → Descriptive Statistics.

Pivot Table.

Use functions like =SUM, =COUNT, =SQRT, = SUMSQ, etc.

Data Analysis → ANOVA: Single Factor.

64.

We have data on a quantitative Y variable in column A of an Excel worksheet. We want column B to say “Pass” if Y is less than or equal to 50, and “Fail” if Y is greater than 50. Which is the correct Excel formula for defining column B, starting with data in row 2?

=IF(A2<50, “Pass”, “Fail”)

=IF(A2<=50, “Pass”, “Fail”)

=IF(A2>50, “Pass”, “Fail”)

=IF(A2<=50, “Fail”, “Pass”)

65.

Which of the following is NOT true about plotting data in time sequence?

It helps identify trends in the data in time sequence.

It can be used to plot both raw data and summary statistics by time period.

It makes it easier to summarize categorical data.

It shows the amount of variation in the data and whether it changes over time.

66.

Which of the following is NOT true about the process capability indices C_p and C_pk?

The process must be in statistical control for the indices to be valid.

Lower numbers are considered better for C_p and C_pk 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.

67.

Which of the following is NOT true about C_p?

C_p compares the 6σ (six-sigma) spread of the process to the width of the spec limits.

The limitation of C_p 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, C_p = 1.0.

When C_p = 1.0, the process is considered a Six Sigma process and “world class” capability.

68.

For a process with C_p = 1.33 and C_pk= 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.”

C_pu and C_pl are not the same for this process.

Centering this process would improve its capability.

69.

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?

70.

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?

71.

Which chart type is recommended for showing the correlation between two quantitative variables?

Histogram

Box and Whisker

Pie

Scatter

72.

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.

73.

Using the file proto builds, test for a difference in percent failing between lots 1 and 2. What is the P value?

0.0092

0.2690

0.0269

0.0962

74.

What is the correct conclusion from the analysis in the previous question?

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.

75.

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

76.

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.

77.

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.

78.

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.

79.

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.

80.

Which of these tools or techniques is NOT used in validating root causes or critical X variables?

Correlation/Regression

Multi-level Pareto Charts

Multi-voting

ANOVA

81.

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.

82.

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.

83.

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.

84.

Which benefit is associated with larger batch sizes?

Fewer changeovers.

Shorter cycle time.

Lower cost of waste.

SIPOC.Less work in process.

85.

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.

86.

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 minutes

30 minutes.

87.

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.

88.

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.

89.

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 happen

Difficulty of knowing if a failure mode has happened.

90.

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.

91.

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.

92.

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.

93.

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.

94.

Using the file proto builds and your results from Question 58 herein, now imagine that the data represent results from a pilot study of the Future State process. Find the upper 95% confidence bound on the population percent failing. Which of the following gives the correct percentage?

77%

23%

84%

31%

95.

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.

96.

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.

97.

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.

98.

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.

99.

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 chart

X-bar and s chart (average and standard deviation)

IX and MR chart (individual and moving range)

X-bar and R chart (average and range)

100.

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.