Question 1

Lean systems eliminate waste but can result in all of the following except?

Accepted Answer

The whole point of lean systems is to reduce inventory levels, not increase them. Therefore, the correct answer is B.

Question 2

In Six Sigma, the goal of quality perfection is represented by having a process sample average that falls below a control limit that is placed how far above the true process mean?

Accepted Answer

C

Question 3

For lean practices to be successful, all of the following must meet or exceed quality requirements except?

Accepted Answer

MRO inventory (maintenance, repair, and operating supplies) is not directly related to the final product quality and can be sourced from outside suppliers as needed. However, parts/assemblies, work-in-process, and finished goods must all meet or exceed quality requirements to ensure the final product meets customer expectations.

Question 4

Approximately what percentage of Fortune 500 firms currently use Six Sigma?

Accepted Answer

Approximately 50% of Fortune 500 firms have implemented Six Sigma methodologies to improve their business processes and enhance quality management.

Question 5

A typical automobile may have approximately how many OFD?

Accepted Answer

The answer of A typical automobile may have approximately how...

Question 6

Which U.S. automaker was the first to adopt Six Sigma?

Accepted Answer

Ford is credited with adopting Six Sigma in the late 1990s, becoming one of the first major automakers to embrace the methodology.

Question 7

In Six Sigma, OFD refers to?

Accepted Answer

OFD (Opportunities for Defects) refers to the number of chances a defect could occur in a given process. It is used to identify the potential areas of improvement in a process to reduce the number of defects and improve overall quality.

Question 8

Which of the following is an example of a lean production initiative?

Accepted Answer

Rearranging factory floor layouts is a lean production initiative as it focuses on optimizing the flow of materials and minimizing waste in production processes.

Question 9

In Six Sigma, DPMO refers to?

Accepted Answer

DPMO stands for Defects per million opportunities. It is a metric used to measure the number of defects per million opportunities to produce a defect-free unit or product. It is a key performance indicator in Six Sigma methodology, where the goal is to reduce defects and minimize variation in processes.

Question 10

The target maximum defect rate of a Six Sigma process is how many parts per million?

Accepted Answer

The target maximum defect rate of a Six Sigma process is 3.4 parts per million. This means that there should be no more than 3.4 defects per million opportunities in the process. This level of performance corresponds to a defect rate of 0.00034% and a sigma level of 6.

Question 11

A kayak manufacturer produces a product for which there are 35 possible defect opportunities. If in the course of a week the company makes 243 units and discovers 72 total defects, which value below most closely corresponds to the manufacturer's sigma level?

Accepted Answer

First, we need to calculate the defect rate per unit:
Defect rate = Total defects / Total units produced
Defect rate = 72 / 243 = 0.2963

Next, we need to calculate the DPMO (Defects per Million Opportunities):
DPMO = Defect rate x Number of defect opportunities x 1,000,000
DPMO = 0.2963 x 35 x 1,000,000
DPMO = 10,368,250

Using a Z-table or a Six Sigma Calculator, we can find that a DPMO of 10,368,250 corresponds to a sigma level of approximately 4. Therefore, the best choice is C.

Question 12

A toy manufacturer produces a product for which there are 10 possible defect opportunities. If in the course of a week the company makes 1,000 units and discovers 17 total defects, what is the manufacturer's DPMO?

Accepted Answer

The answer of A toy manufacturer produces a product for...

Question 13

Successful Six Sigma projects are likely to accomplish all of the following except?

Accepted Answer

Successful Six Sigma projects aim to reduce variation, improve quality, increase efficiency, and ultimately improve customer satisfaction. However, increasing inventory levels is not an objective of Six Sigma as it goes against the principle of reducing waste and improving efficiency.

Question 14

A toy manufacturer produces a product for which there are 10 possible defect opportunities. If in the course of a week the company makes 1,000 units and discovers 17 total defects, which value below most closely corresponds to the manufacturer's sigma level?

Accepted Answer

First, we need to calculate the defect rate (DR):

DR = Total Defects/Total Opportunities

DR = 17/10,000

DR = 0.0017

Next, we need to calculate the Defects Per Million Opportunities (DPMO):

DPMO = DR * 1,000,000

DPMO = 0.0017 * 1,000,000

DPMO = 1700

Using this DPMO value, we can refer to a sigma level table to find the corresponding sigma level.

According to the table, a DPMO of 1700 corresponds to a sigma level of 4.5. Therefore, the closest value below is C: 4.5.

Question 15

Which company was the first large-scale adopter of Six Sigma?

Accepted Answer

GE was the first large-scale adopter of Six Sigma, under the leadership of Jack Welch in the late 1990s.

Question 16

A five sigma level would have an expected DPMO of?

Accepted Answer

The answer of A five sigma level would have an...

Question 17

DPMO is calculated as?

Accepted Answer

DPMO (Defects per Million Opportunities) is calculated as the number of defects divided by the total number of opportunities for those defects to occur, multiplied by one million. In this equation, OFD (Opportunities for Defects) per unit is equivalent to the total number of opportunities for defects to occur in one unit of output. Therefore, DPMO = number of defects / (OFD per unit)(number of units).

Question 18

A quality philosophy that drives a firm to lower prices, higher quality, and fast response is referred to as?

Accepted Answer

Six Sigma is a quality philosophy that drives a firm to lower prices, higher quality, and fast response.

Question 19

Which company pioneered Six Sigma?

Accepted Answer

Motorola is credited with pioneering Six Sigma in the 1980s, using it as a quality management system to improve their manufacturing processes. While other companies like GE, IBM, and GM have also adopted Six Sigma, they did not originate the methodology.

Question 20

A kayak manufacturer produces a product for which there are 35 possible defect opportunities. If in the course of a week the company makes 243 units and discovers 72 total defects, what is the manufacturer's DPMO?

Accepted Answer

The answer of A kayak manufacturer produces a product for...

Quiz 13: Six Sigma Quality Management