Green Belt Exam WARNING: If you refresh your browser or close this page before completing the exam, your answers will not be saved! 123456789101112131415161718192021222324252627282930313233343536373839404142434445464748495051 Green Belt Exam (SES) 1. Your name (you will not get credit for your answers if you don't enter your name!) Check 2. A problem statement should have which of the following characteristics? (Select all that apply.) Be a factual description of the problem Include a diagnosis of the cause Include opinion in addition to hard data Include specific examples 3. A SIPOC diagram is a concise, visual way to show which of the following? Samples-Impact-Proportions-Overproduction-Causes Standard Deviation-Innovation-Percentage-Outputs-Counts Suppliers-Inputs-Process-Outputs-Customers Search-Identify-Propose-Organize-Check 4. A well written impact statement should do which of the following? (Select all that apply.) Describe the cost of doing nothing Help the organization prioritize the improvement activity relative to other possible projects Include your opinion about why this project is better than others 5. A good goal statement should include which of the following? (Select all that apply.) A verb indicating what the project is trying to achieve (e.g., “reduce”, “increase”, etc.) An adjective indicating the relative scale of the problem (e.g., “decent”, “terrible”) A noun indicating what is being changed (e.g., “scrap”, “system up-time”, etc.) The baseline level of performance and the target level of performance (e.g., “increase XX from 90% to 98%”) A date indicating when the goal should be achieved. 6. When collecting data which of the following approaches is preferred? Convenience sampling Voluntary response sampling Random sampling Targeted sampling with interpolation 7. The role of the project champion is which of the following? Tell the team the cause of the problem so they don’t waste time Verify the hypothesis test calculations Take the lead in writing new standards Help the team overcome organizational barriers 8. When a DMAIC team first starts working to understand the root causes of problems, a critical first step is which of the following? Have each team member suggest a set of possible solutions Solicit opinions on the likely cause of the problem Create and agree on the current state process map Decide which variables to experiment with 9. Useful tools for root cause problem solving include which of the following? (Select all that apply.) Asking “who?” five times A fishbone (or Ishikawa) diagram Asking “why?” five times Trying what worked last time 10. In order to keep the DMAIC project on track, which of the following approaches are recommended? (Select all that apply.) Frequent check-ins with the champion, at least once during each phase, if not more often A documented, shared, and frequently updated project plan Frequent team meetings to share learnings and task status Team working sessions to efficiently advance the project through real-time collaboration 11. Every organization has a set of “core processes”, often referred to as “Value Streams”. Value Streams can be defined as: “All activities, both ________ and ________ that an organization carries out to create and deliver their products and/or services to their customers and stakeholders.” Select the answers below that correctly fill in the blanks. value-added time-consuming non-value-added expensive 12. In addition to managing the project plan, a DMAIC project manager should also do which of the following? Conduct a stakeholder analysis Review salaries of the team members Perform detailed reviews of each team member’s notes Make sure they personally complete all of the tasks 13. Using this data construct an I-MR chart (use all data to calculate mean and control limits). How many out-of-control conditions are represented on the Individuals chart? Zero One Three Five 14. The chart below (click here to see a larger version) represents the time to complete a task. A process improvement was implemented starting at point 31. What can we reasonably conclude about the new process starting from that point? All the people previously involved in the process were replaced Quality has decreased The standard deviation has increased The mean has decreased 15. The control chart below (click here to see a larger version) tracks a process that had an improvement implemented at point 31. Now that the improvement appears to have been sustained for some time, what action would you recommend to make sure that you can see out-of-control conditions in the future? Delete any outlier points Recalculate the control limits starting at point 31 Eliminate the lower control limit Investigate what happened at point 5 16. A plant manager is frustrated with the number of defects they’re seeing in product assemblies and they’re concerned that the number may be increasing. They want to establish a control chart to monitor this metric. Which chart is the best choice? X-Bar R chart C-Chart P-Chart X-Bar S chart 17. The IT department monitors all remote network connection attempts from employees. They want to establish a control chart to monitor time-to-connect, which they know is a critical metric. Which chart is the best choice? IMR chart U-chart NP-chart P-chart 18. A manufacturing plant has set up a new assembly cell and wants to track build times using a control chart. To gather data, they have a quality control engineer who can periodically sample build times. They would like to make sure the chart data is Normally distributed. Which chart is the best choice? IMR chart C-chart X-Bar R chart NP-chart 19. HR has initiated a new time-tracking system and has trained all employees on its use. They want to track the proportion of correctly submitted time sheets each week to make sure that they can see any out-of-control situations and respond to them quickly. Which chart is the best choice? P-chart IMR chart Eye chart X-Bar S chart 20. A process has an upper specification of 15, a mean of 13.5, and a standard deviation of 1. What is the Cp (process potential)? 0.25 0.5 0.83 The Cp cannot be calculated with the information provided 21. A process has an upper specification of 15, a mean of 13.5, and a standard deviation of 1. What is the Cpk (process capability)? 0.25 0.5 0.83 The Cpk cannot be calculated with the information provided 22. Which of the following is not required to calculate Cpk? A calculator At least one customer specification limit Normally distributed data Variable/measured data 23. Cp, or process potential, compares which two things? Cost and benefit Voice of the customer and project cost Voice of the customer and voice of the process Error rate and voice of the process 24. A project leader is trying to help a group of customers prioritize a list of their requirements, but they can’t agree among themselves. What tool(s) could the project leader use to facilitate the discussion? (Select all that apply.) Spaghetti diagram Pairwise comparison Scatter plot Multi-voting 25. DMAIC teams often identify more potential countermeasures than they can reasonably implement. Which tool is helpful in narrowing the focus to the critical few? A project plan A control plan A SIPOC diagram An effort vs. impact matrix 26. What are characteristics of a good FMEA? (Select all that apply) It should ensure that each failure mode has one, and only one cause It estimates the severity, likelihood of occurrence, and likelihood of detection for each failure mode It should include a list of who is at fault if something goes wrong It should include a description of what can go wrong 27. What are characteristics of good visual management? (Select all that apply) Visuals should require extensive training to understand Visuals should make the current status clear “at a glance” Visuals should be updated no more than annually Visuals should drive action 28. As DPMO goes down... ...the width of the customer specification gets smaller ...sigma capability goes up ...Cpk goes down ...the width of the customer specification gets larger 29. A typical control plan should include which of the following? (Select all that apply.) An extensive history of the DMAIC improvement project A description of the key process metrics and a measurement plan A glossary of Lean terms and definitions A current state process map 30. Before a DMAIC project can be closed out, which of the following must take place? (Select all that apply) Formal hand-off of the control plan to the process owner Process documentation updated Training for operators on any changes made to the process Complete the Define phase of the next process improvement opportunity 31. Which of the following can be used to track process capability for attribute/binary data? PPM MSA Cpk FMEA 32. A rocket company is developing a new, low-cost, maneuvering engine intended for mass production. A critical-to-quality characteristic is the thickness of the engine nozzle. Computer modeling has shown that for optimal weight and performance the thickness of the nozzle should be no less than 5.5 cm and no greater than 5.8 cm. To validate their ability to measure engine nozzle thickness, an MSA was conducted and a total of 8 test engines were measured two times each by three engineers (appraisers). Based on the the results of your analysis (click to download data), which appraiser is struggling most with Repeatability? Appraiser #1 Appraiser #2 Appraiser #3 33. A rocket company is developing a new, low-cost, maneuvering engine intended for mass production. A critical-to-quality characteristic is the thickness of the engine nozzle. Computer modeling has shown that for optimal weight and performance the thickness of the nozzle should be no less than 5.5 cm and no greater than 5.8 cm. To validate their ability to measure engine nozzle thickness, an MSA was conducted and a total of 8 test engines were measured two times each by three engineers (appraisers). Based on the the results of your analysis (click to download data), what is the largest contributor to the variation? Repeatability The parts themselves Reproducibility Operator/part interactions 34. A rocket company is developing a new, low-cost, maneuvering engine intended for mass production. A critical-to-quality characteristic is the thickness of the engine nozzle. Computer modeling has shown that for optimal weight and performance the thickness of the nozzle should be no less than 5.5 cm and no greater than 5.8 cm. To validate their ability to measure engine nozzle thickness, an MSA was conducted and a total of 8 test engines were measured two times each by three engineers (appraisers). Based on the the results of your analysis (click to download data), which category of measurement variation is of most concern? Repeatability Reproducibility 35. A rocket company is developing a new, low-cost, maneuvering engine intended for mass production. A critical-to-quality characteristic is the thickness of the engine nozzle. Computer modeling has shown that for optimal weight and performance the thickness of the nozzle should be no less than 5.5 cm and no greater than 5.8 cm. To validate their ability to measure engine nozzle thickness, an MSA was conducted and a total of 8 test engines were measured two times each by three engineers (appraisers). Based on the the results of your analysis (click to download data), which results indicate the measurement system appears unacceptable? (click here to refer to the MSA metrics slide) % Total exceeds acceptable limits Resolution is below acceptable limits % Tolerance exceeds acceptable limits All of the above 36. A semiconductor company decides to test their new signal processor against a competitor's offering (the SuperX processor). They want to determine if the two processors have significantly different standard deviations. The test data for both processors is normally distributed. Analyze the data (click to download the data). True or False: Using an alpha of 0.05, you can reject the null hypothesis (H0) and accept the alternative (H1) that the two processors have different standard deviations. True False 37. The manager of the Finance department at a small software company believes that the number of purchase orders with mistakes has increased recently. She suspects that this may be due to a new hire joining the team. To test this statistically, she pulls data from the two months prior to the new hire joining the team, and the month after. During the two months before the new hire, 30 out of 207 purchase orders were defective. During the month since the new hire joined the team, 17 out of 77 were defective. She runs a hypothesis test to determine if the proportion of defectives has really changed. What should the manager conclude based on the results of the analysis? Looking at the raw data, the manager must conclude that the new hire is clearly causing more defective purchase orders Stick with H0, there is not enough evidence to conclude that the proportions are different Reject H0 and accept H1, that the proportions are different 38. A construction company sources composite wooden beams from different suppliers. They have noticed three different types of defects in the beams: cracks, chips, and holes. They analyze the data (click to download the data) to see if there is a statistically significant correlation between supplier and defect type. Based on the results of the analysis, what conclusions can they draw? (Select all that apply) Supplier A and Supplier C use the same kind of wood There seems to be a correlation between supplier and defect type Supplier B is producing more cracks than would be expected if there were no correlation Supplier A is producing fewer holes than would be expected if there were no correlation 39. WidgetPro, Inc. is a supply company that regularly bids on new jobs for their customer, a major manufacturer of heavy equipment. The process involves submitting multiple documents in a bid package that must meet certain criteria. Depending on the specifics of the bid, the bid packages can be approved by different people (appraisers) before submission. Recently, the manufacturer has started to reject several bid packages for non-compliance to their standard. An attribute MSA was conducted to see if the bid appraisers were reliably able to distinguish good bid packages from bad ones. Five appraisers each reviewed 12 previously submitted bid packages two times each (half of the bid packages selected for the MSA were known to be good and half were known to be bad). Management wants to retrain the bid appraisers. Based on your analysis of the MSA data (click to download data), who would you recommend they choose to help lead the retraining? Appraiser 1 Appraiser 2 Appraiser 3 Appraiser 4 Appraiser 5 40. WidgetPro, Inc. is a supply company that regularly bids on new jobs for their customer, a major manufacturer of heavy equipment. The process involves submitting multiple documents in a bid package that must meet certain criteria. Depending on the specifics of the bid, the bid packages can be approved by different people (appraisers) before submission. Recently, the manufacturer has started to reject several bid packages for non-compliance to their standard. An attribute MSA was conducted to see if the bid appraisers were reliably able to distinguish good bid packages from bad ones. Five appraisers each reviewed 12 previously submitted bid packages two times each (half of the bid packages selected for the MSA were known to be good and half were known to be bad). Based on your analysis of the MSA data (click to download data), which statement is true? The appraisers are more likely to accept a bad package than to reject a good package The appraisers are more likely to reject a good package than to accept a bad package Right or wrong, the appraisers are perfectly consistent in their judgements All of the appraisers need additional training 41. An aerospace company manufactures bolts for installation on orbital rockets. The bolts have an upper limit on weight of 30 grams. An initial test run showed that the majority of the bolts exceeded the limit. A de-burring operation was added to remove burrs and other minor surface imperfections. Seventeen samples were selected and were weighed both before and after the de-burring operation and the differences calculated (click to see data). Calculate the 99% confidence interval for the average difference. Based on your calculation, what can we say about the de-burring operation? It's impossible to say if the de-burring operation is making any difference in the weights The de-burring operation is clearly not changing the weights of the bolts The bolts are all out of spec We can be over 99% confident that the de-burring operation is making a difference in the weights 42. A javelin thrower wants to determine the average distance of his throws -- plus or minus 2 meters -- to establish a baseline against which he can measure future improvement. Based on some historical information, he and his coach estimate that the standard deviation of his throws is about 6 meters. How many throws should he make to estimate his average distance, plus or minus 2 meters, with 95% confidence? 15 25 35 45 43. The 8 classic wastes of Lean are (select the answers below that correctly fill in the blanks): Transportation ______________ Motion ______________ Waiting Over-production ______________ ______________ Meetings Inventory Overcommitment Underutilization Under-processing Over-processing Defects Distraction 44. The process map approach designed to highlight the responsibility for each task is which of the following? Spaghetti diagram Traditional process flow Swimlane process map Time-value map 45. Takt time shows us the pace of customer demand. Which of the following is the correct way to calculate takt time? Cycle time divided by lead time plus parts required Available time divided by parts required Number of operators times parts required Lead time minus cycle time 46. Using the House of Quality model, we are able to do which of the following? Translate customer needs and wants into measurable KPIs Convert CTQs into Normally distributed data Narrow down a list of potential countermeasures Determine product capability 47. The practice of removing inefficiency from a workplace by sorting materials, removing what's unnecessary, setting things in order, and sustaining that organization over time, is known as which of the following? 6M 4P 5S 2D 48. When we take samples from a larger population and plot them on a histogram, they create a child distribution. The Central Limit Theorem tells us that which property of the child distribution will be the same as that of the parent distribution? The variance The median The mean The standard deviation 49. When we take samples from a larger population and plot them on a histogram, they create a child distribution. The Central Limit Theorem tells us that if the sample size is sufficiently large, the child distribution will... ...have the same shape as the parent ...be normally distributed ...have the same standard deviation as the parent ...be exponentially distributed 50. When we are comparing data sets using Hypothesis Testing, the alpha value represents how confident we need to be to reject our default hypothesis (H0) and accept the alternative (H1). If we want to be 95% confident in our conclusion, what should we set our alpha value to? 0.1 0.05 0.95 0.5 51. When considering the Cost of Poor Quality (COPQ), which of the following costs is most damaging for a company? Internal failure costs (i.e., scrap) Appraisal costs (i.e., inspection) Prevention costs (i.e., error proofing) External failure costs (i.e., bad parts getting to customers) Your score is 0%
