Question 1

Explain each phase of the DMAIC methodology.

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Question 2

Explain what is meant by "Six Sigma quality" with respect to defect expectations.Draw a picture that relates Six Sigma quality to the notions of design tolerance and process variability.

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Question 3

Some have argued the Six Sigma programs are merely repackaged versions of older quality improvement programs that originally accompanied TQM initiatives in the 1980s.Present arguments that both support and refute this view.

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Question 4

Which of the following is NOT a tool used in lean production?

Accepted Answer

Push production is actually the opposite of lean production, which focuses on pull production where products are produced only when there is demand. The other three options (the 5S's, visual controls, efficient layout and standardized work) are tools commonly used in lean production.

Question 5

_____ focuses on the elimination of waste in all forms,including defects requiring rework,unnecessary processing steps,unnecessary movement of materials or people,waiting time,excess inventory,and overproduction.

Accepted Answer

The focus on eliminating waste in all forms is a core principle of the Lean approach to business management. Six Sigma and Deming Quality Circles also focus on improving quality and efficiency, but they do not specifically emphasize waste reduction to the same degree as Lean. Kaizen is a continuous improvement process that can be incorporated within any of these approaches, but it is not a standalone method for waste reduction.

Question 6

Describe the categories of problems that have been found to be approached by Six Sigma methodology.

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Question 7

Specifications for the density of dustless chalk used in classrooms is 3.5 ± 1.5. (The unit of measure is grams per centimeter²,or g/cm².)A random sample of 100 pieces of chalk was selected and the density of each piece in the sample was recorded.The sample average was equal to 3.6 and the sample standard deviation was equal to 0.75.A histogram of the sample data is given below.
  
a.How many pieces of chalk in the sample are considered defective (not within the specifications)?
b.Using your response to the above question,what is the dpmo value for this process?
c.According to the concepts of Six-Sigma Quality,what the quality level for this process? (Use the appropriate table provided in the textbook.)

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Question 8

Lean approaches focus on:

Accepted Answer

Lean approaches aim to eliminate waste in all forms, including non-value-added activities, unnecessary inventory, overproduction, defects, and transportation. While they may also involve employee involvement and innovation in product design, the primary focus is on reducing waste to increase efficiency and quality. Option A and D are incorrect because Lean Approaches also focus on value-added activities.

Question 9

Explain the concept of lean production.Describe its relation to Six Sigma.

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Question 10

Some people assert that Six Sigma quality levels represent overkill in most industry situations.Counter this assertion with industry examples where less than six sigma quality would significantly impact industry performance and perhaps social welfare at large.

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Question 11

The number of defects found in 20 samples of 100 Frost Ice-cream Company flavors taken on a daily basis from a production line over a five-week period is given below.Plot these data on a run chart,computing the average value (center line),and the upper control limit.Do you suspect that any special causes are present? Why?

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Question 12

_____ is used to interpret scatter diagrams.

Accepted Answer

Statistical correlation analysis is used to interpret scatter diagrams by measuring the strength of the relationship between two variables. It can help identify patterns and trends in the data, as well as indicate the direction and extent of the relationship. Process mapping, benchmarking, and cause and effect analysis may also be useful tools in analyzing data, but they are not specifically tailored to interpreting scatter diagrams.

Question 13

_____ refers to rapid changeover of tooling and fixtures in machine shops so that multiple products in smaller batches can be run on the same equipment.

Accepted Answer

Single minute exchange of dies (SMED) is a lean manufacturing technique that refers to the rapid changeover of tooling and fixtures in machine shops so that multiple products in smaller batches can be run on the same equipment. SMED reduces setup time, improves production flexibility, and enables just-in-time manufacturing.

Question 14

_____ provide clues about the characteristics of the parent population from which a sample is taken.

Accepted Answer

Histograms provide visual representation of the frequency distribution of a set of data. They can provide insights into the shape, central tendency, and dispersion of the data, which can in turn give clues about the characteristics of the parent population from which a sample is taken. Pareto analyses and check sheets are tools used for quality control, while scatter diagrams are used to explore the relationship between two variables. Thus, A) Histograms is the best choice.

Question 15

Explain why,in the initial stages of Six Sigma implementation in a firm,it is advantageous to choose project that have a high likelihood of success.

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Question 16

Which of the following is NOT a characteristic of a Six Sigma project?

Accepted Answer

While customer feedback is important in Six Sigma projects, it is not necessary to have a customer-panel to assess incremental improvements at different stages of the implementation. Therefore, choice C is not a characteristic of a Six Sigma project.

Question 17

A _____ is a _____ of the data from the largest frequency to the smallest.

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Question 18

Analysis of customer complaints at Flash Apparel Company revealed errors in five categories.Data is provided below.Construct a Pareto diagram for these data.What conclusions can you reach?

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Quiz 11: Six Sigma And Process Improvement