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IASSC Lean Six Sigma - Black Belt Questions and Answers

Question 1

An example of the waste of mismanaged Inventory is __________.

Options:

A.

Capital costs of money

B.

Value decrease from aged inventory

C.

Cost of storage space

D.

All of these answers are correct

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Question 2

Kaizens or Kaikakus and Six Sigma projects are intended to create incremental process improvements versus breakthrough, significant improvements.

Options:

A.

True

B.

False

Question 3

At the very initiation of a project a Belt must develop a concise _______________ that states at a high level the area of concern and why it is important this issue be improved.

Options:

A.

Business Case

B.

Project Doctrine

C.

Management Justification

D.

Process Owner Disclosure

Question 4

Using this data calculate the percentage of DPU.

Data: 763 defects, 18,000 units.

Options:

A.

2.12

B.

3.42

C.

4.24

D.

5.72

Question 5

An operator is measuring the distance between two points. Which is most likely to be influenced by the operator?

Options:

A.

Precision of the measurement

B.

Accuracy of the measurement

C.

Calibration of the instrument

D.

All of these answers are correct

Question 6

For Attribute Data, Process Capability is defined as the average proportion of nonconforming products.

Options:

A.

True

B.

False

Question 7

When doing Hypothesis Testing on Non-normal data Belts will use a ________________ to compare more than two sample proportions to each other.

Options:

A.

Z score Table

B.

Sakami Table

C.

Mean-to-Mode Analysis

D.

Contingency Table

Question 8

Which of these might contribute to similar distributions having Unequal Variance?

Options:

A.

Extreme tails

B.

Outliers

C.

Multiple Modes

D.

All of the above

Question 9

When a Belt implements an improvement that is automated thus requiring no particular understanding for use he has applied which Lean tool?

Options:

A.

Mistake Proofing

B.

Kaizen Event

C.

5S

D.

None of the above

Question 10

The primary objective in removal of waste is to improve the Order Production Cycle where the time from _________________ to the time of receipt of payment is compressed.

Options:

A.

Shift start

B.

Product development

C.

Receipt of an order

D.

New fiscal year

Question 11

Control Charts were developed by Dr. Shewhart to track data over time. To detect Special Cause variation the Control Charts use which of these?

Options:

A.

Data shift analysis

B.

Outlier analysis methods

C.

Center Line and Control Limits

D.

None of the above

Question 12

The Japanese born function of a Kaizen event utilizes a specific, step-by-step approach meant to bring about major changes to a process.

Options:

A.

True

B.

False

Question 13

An ANOVA used across many dependent variables could increase the Beta risk.

Options:

A.

True

B.

False

Question 14

A valid Multiple Linear Regression (MLR) is characterized by all of these except _______________________.

Options:

A.

It is an assumption that the X’s (inputs) are not correlated to each other

B.

The X’s (inputs) are assumed to be independent of each other

C.

MLR is conducted based on a deliberate form of experimentation

D.

The Residuals from MLR analysis have to be Normally Distributed

Question 15

Which statement is NOT correct about the Fitted Line Plot shown here?

Options:

A.

The independent variable is the reactant

B.

If the reactant was 6 units, with 95 % confidence we would expect a minimum yield of 100 units

C.

With at least 95% confidence, we can expect less than 10 units of Yield when the reactant is at a value of 1

D.

A reactant value between 2 and 4 units yields around 20 to 40

E.

When the reactant increases, the expected yield would increase

Question 16

Some of the sources for different types of error that can be quantified using Statistical Analysis are which of these?

Options:

A.

Error in sampling

B.

Bias in sampling

C.

Error in measurement

D.

All of the above

Question 17

When conducting a Hypothesis Test using Continuous Data the proper sample size is influenced only by the extent to which we need to assess a Difference to be detected but not the inherent variation in the process.

Options:

A.

True

B.

False

Question 18

The English words used for the 5S’s are __________ , _____________ , Shining, Standardizing and Sustaining. (Note: There are 2 correct answers).

Options:

A.

Shaping

B.

Sorting

C.

Shifting

D.

Straightening

Question 19

The Hardware Store ordered ten lawn mower from the manufacturer and just before shipping the manufacturer found one to have a motor that wouldn’t start. For the manufacturer this would be categorized as what type of cost?

Options:

A.

Internal Failure Costs

B.

External Failure Costs

C.

Prevention Costs

D.

Appraisal Costs

Question 20

Which Experimental Design typically is most associated with the fewest number of input variables or factors in the design?

Options:

A.

Response Surface design

B.

Full Factorial design

C.

Simple Linear Regression

D.

Fractional Factorial design

Question 21

Of the various types of data shown which is NOT representative of Variable Data.

Options:

A.

Child’s height is 4 foot 3 inches

B.

Three employees wore hard hats

C.

Car burned 2.7 gallons of gasoline

D.

Train was going 140 kilometers per hour

Question 22

Measurement __________ is defined as the difference between the observed and the expected values for a given set of data.

Options:

A.

Breadth

B.

Linearity

C.

Range

D.

Bias

Question 23

The Waste of Overproduction is defined as ______________________.

Options:

A.

The unnecessary movement of people and equipment

B.

The liability of materials that are bought, invested in and not immediately sold or used

C.

Producing more than the next step needs or more than the customer buys

D.

The extra movement of material

Question 24

An operator checks that all boxes being packed contain enough products to fill the box. However, each box getting filled has a different number of products in it. This is a Reproducibility problem, not a Repeatability problem.

Options:

A.

True

B.

False

Question 25

Some of the sources for different types of error that can be quantified using Statistical Analysis are ___________________.

Options:

A.

Error in sampling

B.

Bias in sampling

C.

Error in measurement

D.

All of these answers are correct

Question 26

The Greek letter “sigma” is used by mathematicians to signify _____________.

Options:

A.

Curve Width

B.

Numerical Average

C.

Standard Deviation

D.

Data Spread

Question 27

Which of these elements are not included in Implementation plans?

Options:

A.

Work breakdown structure

B.

Cost/Benefit ratios

C.

Risk management plans

D.

Planned audits of work completion

Question 28

Which statement(s) are correct about the Pareto Chart shown here for the DOE analysis? (Note: There are 2 correct answers).

Options:

A.

It is unknown from this graph how many factors were in the Experimental Design

B.

The factors to keep in the mathematical model are E, D, DE, BD and B with an alpha risk equal to 2.06

C.

The effects to keep in the mathematical model are E, D, DE, BD and B with an alpha risk equal to 0.05

D.

The factors to keep in the mathematical model with a 5% alpha risk are BE, AB, A and AD

Question 29

If an experiment has 5 factors and no replicates for a 2-level Experimental Design with 16 experimental runs which statement(s) are correct? (Note: There are 3 correct answers).

Options:

A.

The Main Effects for the 5 factors are not aliased or confounded but the 2-way interactions are confounded with the 3-way interactions

B.

The Main Effects are confounded with only 4-way interactions

C.

The Experimental Design is half-fractional

D.

The experiment has 8 experimental runs with the first factor at the high level

E.

The experiment has only 4 experimental runs with the 5th factor at the high level

Question 30

The validity of the decision made with Hypothesis Testing is dependent upon all of these except ___________________.

Options:

A.

Beta risk

B.

Alpha risk

C.

Range of data

D.

Sample size

Question 31

Choose those characteristics of a Simple Linear Regression (SLR) Analysis that are applicable. (Note: There are 3 correct answers).

Options:

A.

The Correlation Coefficient is always greater than the Regression Coefficient in a SLR

B.

General Regression Analysis deals only with Continuous Data

C.

Non-linear Regressions can explain curvature when with more statistical confidence than Linear Regressions

D.

SLR can help quantify the significance of variation in X that influences the variation in Y via a mathematical equation

E.

A Correlation does not explain causation but a Regression Analysis with a statistically valid mathematical equation does explain causation

Question 32

Cost of Poor Quality (COPQ) can be classified as Visible Costs and Hidden Costs. All these items are Hidden Cost except __________________.

Options:

A.

Lost Customer Loyalty

B.

Returns

C.

Time Value of Money

D.

Late Delivery

Question 33

Appropriate measures means that measurements are ______________.

Options:

A.

Representative

B.

Sufficient

C.

Contextual

D.

Relevant

E.

All of these answers are correct

Question 34

With Measurement System Analysis we are concerned with two issues that impact the potential variability of the data. They are ____________ and Accuracy.

Options:

A.

Spread

B.

Reliability

C.

Precision

D.

Deflection

Question 35

The two types of data that are to be used in Statistical Analysis are Attribute and Variance.

Options:

A.

True

B.

False

Question 36

In a good Measurement System the most variation will be with part-to-part measurements. What should you do if the majority of variation is associated with the Gage R&R assuming the gage is technically capable?

Options:

A.

Focus on fixing the Repeatability and Reproducibility of the measurement device

B.

Purchase a new machine

C.

Focus on trimming the Part-to-Part variation

D.

Run another MSA test with the machine

Question 37

What conclusion is most correct about the Experimental Design shown here with the response in the far right column?

Options:

A.

No factor has enough statistical confidence greater than 95% to have an impact on the response rate

B.

Constant, Adv and Bev are the only factors statistically affecting the response rate with 95% confidence or more

C.

If the Adv is increased from the low level to the high level, the response rate increases

D.

The response level is statistically concluded to only need the Adv and Bev factors set at the low level to get the largest response rate

E.

This design does not have enough experimental runs to conclude anything as evidenced by the lack of P-values in the MINITABTM output

Question 38

Which of these graphs demonstrates conditions which would be sufficient to enable OCAP for the process? 

Options:

A.

Xbar Chart

B.

Time Series Chart

C.

Neither

D.

Both

Question 39

When we compare short-term and long-term Capability which of these is true?

Options:

A.

Cp is better for the short term

B.

Both short-term and long-term performance are alike

C.

Performance tends to improve over time

D.

Cp is better for the long-term

Question 40

A Belt working in a supply chain environment has to make a decision to change suppliers of critical raw materials for a new product upgrade. The purchasing manager is depending on the Belt’s effort requiring that the average cost of an internal critical raw material component be less than or equal to $4,200 in order to stay within budget. Using a sample of 35 first article components, a Mean of the new product upgrade price of $4,060, and a Standard Deviation of $98 was estimated. Select the answer that best states the Practical Problem.

Options:

A.

If the average cost per component is $4,200 or less, then the purchase manager will introduce the new product upgrade with new components.

B.

If the average cost per component is greater than $4,200, then the purchase manager will introduce the new product upgrade with new components.

C.

Only if the average cost per product upgrade is $4,060, will the purchase manager introduce new product upgrades with new components.

D.

If the average cost per new product upgrade is less than $180, then the purchase manager will introduce the new product upgrade with new components.

Question 41

Which statement(s) are correct about the Regression shown here? (Note: There are 2 correct answers).

Options:

A.

The dependent variable is the outside temperature

B.

The relationship between outside temperature and number of customers per hour is a Linear Regression

C.

The dashed lines indicate with 95% confidence where all of the process data should fall between

D.

The dashed lines indicate with 95% confidence the estimate for the Quadratic Regression Line

E.

The predicted number of customers per hour is close to 5 if the outside temperature is 10 deg C

Question 42

A(n) ______________ is best used to compare a Machine 1 average quality characteristic to the same quality characteristic of Machine 2.

Options:

A.

1-Sample t-test

B.

2-Sample t-test

C.

F test

D.

ANOVA test

Question 43

Use this data to calculate the Z Score. Average of: 92, Standard Deviation: 2, Upper Spec Limit: 101

Options:

A.

0.75

B.

1.5

C.

2.25

D.

4.50

Question 44

What aspects of Measurement Systems Analysis (MSA) studies are applicable when the process used to measure does not damage the part?

Options:

A.

Destructive variable gage R&R and Crossed Study

B.

Destructive variable gage R&R and Nested Study

C.

Nondestructive variable gage R&R and Crossed Study

D.

Nondestructive variable gage R&R and Nested Study

Question 45

A Belt is analyzing data and upon creation of the graphical analysis sees multiple modes. One of the primary reasons this could occur is because the process has experienced a ____________________.

Options:

A.

Significant change from one shift to another

B.

Sizable Measurement System error

C.

Catastrophic failure of some sort

D.

Any one of these

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Total 300 questions