Q1: Which of the following 4 terms includes the other 3
(choose ONE only)
a. Operational Excellence (OpEx)
b. Six Sigma (6σ)
c. Continuous Improvement (CI)
d. Lean Production System (Lean Thinking)
Reason:
Q2: Which approach is always superior (choose ONE only)
a. Waste Reduction
b. Waste Management
c. Waste Disposal
d. Waste Elimination
Reason:
Q3: The objective of a Lean Manufacturing System is to (choose ONE only)
a. Reduce the fat intake of the population leading to improved health
b. Create a respectful and responsive workplace
c. Encourage participation in sport by all employees
d. Increase the share of Value-Adding activities
Reason:
Q4 : Data and Measurement (choose ONE only)
a. Simply creates a lot of work
b. Is too scientific to be used by many
c. Brings understanding to any problem
d. Requires good PC skills
Reason:
Q5: In a LEAN context W. Edwards Deming said that Variation (choose ONE only)
a. Makes life interesting and relieves boredom
b. Is the Enemy of the Process
c. Cannot be modified
d. Is a reality check
Reason:
Q6: Control of Process Inputs (choose ONE only)
a. Reduces manufacturing costs
b. Delivers less variation in the Process / Outputs
c. Is very difficult to achieve
d. Creates too much Variability
Reason:
Process Inputs are (choose ONE only)
a. Both Controllable and Uncontrollable
b. Controllable if you make sufficient effort
c. Always Controllable
d. Uncontrollable without modern computer systems
Reason:
Accuracy may be defined as how close (choose ONE only)
a. The Max and Min are to the Average
b. A particular measurement is to the true value
c. Two lines approach each other
d. The measured values are to each other
Reason:
Common Cause Variation is (choose ONE only)
a. Inherent in the Process Non-Random
b. Explainable and Controllable
c. Inherent in the Process
d. Known and possible to eliminate
Reason:
The application of a LEAN Six Sigma philosophy is (choose ONE only)
a. Only useful in a business context
b. Confined to manufacturing industry
c. Useful in life generally
d. Fulfilment for statisticians
Reason:
Lead Time can be defined as the (choose ONE only)
a. Time taken to deliver the product to the customer
b. Theoretical calculation based on customer demand and available hours
c. Frequency of producing a product at process step
d. Delay in waiting for Maintenance to respond to a breakdown
Reason:
Typically, in early development of processes (choose ONE only)
a. Value Add time equates to the Non-Value Add time
b. Value Add time is much larger than the Non-Value Add time
c. Value Add time is much smaller than the Non-Value Add time
d. We only have one of Value-Add time or Non-Value Add time
Reason:
DMAIC is a methodology specifically aimed at (choose ONE only)
a. Manufacturing cost reduction
b. Performance appraisal of employees
c. Quality improvement in a collaborative manner
d. Structured problem solving
Reason:
Problem definition should always be based on (choose ONE only)
a. Ideas
b. Opinions
c. Data
d. All of the above
Reason:
Identify the three elements of the Define phase from this list (negative marking applies)
a. Creativity
b. Project Charter
c. Inspiration
d. Customer Survey
e. Measurement Strategy
f. Design of Experiment
g. Management excellence
h. Poka Yoke
i. Process Mapping
j. Variation
Reason:
Process Mapping facilitates (choose ONE only)
a. Creation of a Future State Road Map
b. Mutual understanding of the detail of a process
c. Definition of a measurement strategy
d. Preparation of a Cause & Effect Diagram
Reason:
In terms of “Managing to the Future State” which three items from the list below are relevant (negative marking applies)
a. Reality State
b. Future State
c. United State
d. Combined State
e. Targeted Future State
f. Lesser State
g. Measured State
h. Current State
i. Defined State
j. Ill-defined State
Reason:
Identify three Descriptive Statistics from the following list (negative marking applies)
a. Scatter Plot
b. Average
c. Square Root
d. Second Derivative
e. Sum
f. Minimum
g. First Derivative
h. Standard Deviation
i. Histogram
j. Pareto Analysis
Reason:
In a set of data an “outlier” (choose ONE only)
a. Results from Common Cause Variation
b. Is quite a normal occurrence
c. Should not be disregarded
d. Is an Out of Trend result
Reason:
The primary deficiency experienced when using a Histogram is (choose ONE only)
a. Historical data may not be relevant
b. As time passes very quickly, the observer may miss something
c. Time is not represented
d. One never observes a Normal Distribution
Reason:
Which three statements from the list below are true in relation to Cause and Effect Diagrams and problem investigation (negative marking applies)
a. Rarely identifies the true cause of any problem
b. Works best when contributors are robustly challenged whilst presenting ideas
c. Can be used as part of a Brainstorming when investigating a problem
d. Only works when a large group of people are involved
e. Is a technique to systematically analyse a problem
f. Requires substantial software capability in order to execute
g. Needs very experienced people; if not it won’t be successful
h. A range of Potential Causes of a problem are identified
i. Is a form of data visualisation
j. Must be based on a large amount of Statistical Analysis
Reason:
In the Control Phase the focus is on (choose ONE only)
a. Controlling process Inputs
b. Ongoing control of the performance of the process
c. Addressing Uncontrollable Variables
d. Introducing Control Software to the process
Reason:
A Control Plan (choose ONE only)
a. Constitutes a huge commitment in terms of people and time
b. Identifies “acceptable” and “unacceptable” performance in a process
c. Is a rather slow method to identify developing process trends
d. Must be an office-based activities
Reason:
The best Control Chart (choose ONE only)
a. Is one based on use of Excel
b. Provides online monitoring to detect changes in process’s quality
c. Focuses on core data and doesn’t utilise any limits
d. Only works when used by very experienced staff
Reason:
Within the Demings’s PDSA acronym “S” stands for (choose ONE only)
a. Signal
b. Solution
c. Study
d. Structure
Reason:
Within Lean Principles TIMWOODS acronym, “S” stands for (choose ONE only)
a. Suggestion
b. Solution
c. Significant
d. Shape
Reason: Underutilised personnel resources and creativity – ideas that are not listened to, skills that are not used.
Why was the Toyota A3 Form devised? (choose ONE only)
a. Rumoured the inventor refused to read past the first page of any report.
b. Recounting benefits and value from aligned projects
c. Analysis and collaboration efforts for company transactions
d. Form filling within Six Sigma to share project details
Reason:
Within the Gemba stands for (choose ONE only)
a. Investigates where activity is present
b. Indicator of process activity
c. Instrument assessed as part of measurement assurance
d. Improvement to real factory productivity and factory staff morale.
Reason:
Identify three conclusions about a process can be derived from an average and range control chart that cannot be derived from a histogram?
Explain difference between Ppk and Cpk in process capability assessments
Answer:
(Extend this box as needed)