Copy of Yellow Belt Exam

Question 1 of 50

1. Question

When a process has proven itself to function at a ‘Six Sigma Level’ this means there are less than ____ defects per million opportunities for defects.

1.7

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2.6

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3.4

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10

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Question 2 of 50

2. Question

Six Sigma refers to a process whose output has at least 95% of its data points within 6 Standard Deviations from the Mean.

True

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False

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Question 3 of 50

3. Question

The DMAIC approach to problem solving stands for Define, _____, Analyze, Improve, and Control.

Manage

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Measure

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Memorize

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Manipulate

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Question 4 of 50

4. Question

Voice of the Customer is a Lean Six Sigma technique to determine the ______ attributes of a product or service.

Desirable

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Beneficial

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Critical-to-Quality

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Preferred

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Question 5 of 50

5. Question

Which ONE of the following statements best describes what Lean and Six Sigma are really about?

Lean and Six Sigma are about manufacturing products with single piece flow.

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Lean and Six Sigma are about improving our processes so that we can meet customer expectations with our products and services as close to 100% of the time as possible.

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Lean and Six Sigma are about the application of statistical tools and techniques.

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Lean and Six Sigma is about increasing the COPQ of our processes.

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Question 6 of 50

6. Question

Which of the following is probably NOT a usual CTQ (Critical-to-Quality) characteristic for a customer of a restaurant?

Durability of food (Shelf Life)

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Freshness of food

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Price of food

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Speed of Service

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Question 7 of 50

7. Question

When we create a Process Map and want to depict an action step in the process we would use the _____ symbol.

Diamond

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Circle

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Ellipse

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Rectangle

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Question 8 of 50

8. Question

The essence of Lean is to concentrate effort on ______ while improving process flow to achieve speed and flexibility at a lower cost.

Defect removal

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Removing waste

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Overtime reduction

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Rework reduction

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Question 9 of 50

9. Question

A key metric in Six Sigma is the DPMO which stands for _______?

Delayed production metrics output

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Defects by management oversight

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Defects per million opportunities for defects

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Developed production management oversight

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Question 10 of 50

10. Question

The purpose of a Process Map is to identify the complexity of the process and to assist in identifying ______ in the process.

Critical steps

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Line operators

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Test stations

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Defects

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Question 11 of 50

11. Question

At the start of a project we are told to “walk the process” from beginning to end (Gemba Walk). We do this to ______.

Test the workers

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Validate the High Level Process Map

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See what inventory is involved

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Check the repair stations

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Question 12 of 50

12. Question

When we create a Process Map we use a ______ to show the direction of work flow.

Solid line arrow

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Dashed line arrow

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Series of dots

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Double lines

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Question 13 of 50

13. Question

As we begin to describe the things occurring with our process through a Process Map we begin to see some steps that are NVA which stands for ______.

Non-value add

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No violation allowed

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Non-value actions

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Next vehicle action

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Question 14 of 50

14. Question

Poka Yoke devices help us to obtain:

Near zero defect conditions

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Reduced costs

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Higher quality

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All of the above

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Question 15 of 50

15. Question

Which of the wastes identified by Taiichi Ohno describes the water of a downstream worker who cannot continue the next step of a process until a large batch has finished processing in the upstream operation?

Over production

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Over processing

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Waiting

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Motion

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Question 16 of 50

16. Question

What Lean and Six Sigma tool is used to organize and create order in the layout of the tools and equipment in the workplace?

SMED

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5S

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Kanban

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Muda

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Question 17 of 50

17. Question

Lean Principles defines for us at least ______ specific areas where waste typically exists in our processes.

Three

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Five

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Seven or Eight

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Two

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Question 18 of 50

18. Question

It is recommended that when beginning a 5S program it be started in a small ‘pilot’ work area for learning and demonstration purposes and then it is extended throughout the business.

True

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False

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Question 19 of 50

19. Question

One of the 5S approaches to eliminating waste is to minimize work activities that are out of the ordinary thereby requiring unusual decisions and actions to accomplish the correct things. This 5S tool is called ______.

Standardizing

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Scheduling

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Sustaining

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Sorting

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Question 20 of 50

20. Question

To minimize waste through the application of Lean Principles we do which of the following?

Have clear visual tools and signals so that all workers can see when waste is being produced.

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Keep the work area clean and organized.

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Maintain the correct amount of inventory using a Kanban system.

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All these answers are correct.

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Question 21 of 50

21. Question

One Lean Principle is that process improvement is a continuous series of small changes requiring workers and management to always be on the lookout for ways to reduce waste, improve throughout and make processes better for both workers and customers. This Lean Principle is known as ______.

Kaizen

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Ishikawa

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Kanban

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Muda

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Question 22 of 50

22. Question

Which of the following activities is an example of non-value-added?

Rework

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Inspection

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Packing

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Setup

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Question 23 of 50

23. Question

What is the Japanese word for waste?

Mode

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Muri

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Muda

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Mura

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Question 24 of 50

24. Question

A process with a process Sigma level of 6 over the long term would be expected to produce which of the following?

Approximately 3.4 defects per 1 Million Products

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Approximately 3.4 defects per 1 Million Defect Opportunities

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Approximately 3.4 defects per 1 Million Success Opportunities

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Approximately 3.4 defects per 1 Million Process Opportunities

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Question 25 of 50

25. Question

What is the minimum level of training that a member of a Lean and Six Sigma process improvement team requires?

Black Belt

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Master Black Belt

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Yellow Belt

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Green Belt

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Question 26 of 50

26. Question

A product or service that does not meet the expectations of the customer is called a ______.

Defective product or service

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Defect

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Problem

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Reject

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Question 27 of 50

27. Question

It is always important to understand who is the customer of a process. Which of the following is the best definition of ‘The Customer?’

Anyone who supplies products of services to the process

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Stakeholders of the process

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Anyone who receives a product or service, or could receive a product of service from the process

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People or groups who are responsible for the output of the process

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Question 28 of 50

28. Question

The Lean and Six Sigma concept called ‘Critical to Quality’ (CTQ) always focuses on what?

Reducing product variation

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Reducing in-process inventories and minimizing product touch times

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Meeting the specific requirements of the customer

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Minimizing shipping damage

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Question 29 of 50

29. Question

What basic quality tool would be most applicable for a work team to use when there is a need to follow procedures and work instructions more closely?

Fishbone Diagrams and Control Charts

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Data Sheets and Histograms

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Pareto Charts and Affinity Diagrams

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Standard Operating Instructions and Visual Management

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Question 30 of 50

30. Question

Finish this sentence:

As part of the Lean and Six Sigma improvement in processes, we aim to reduce the “Batch and Queue” method of production and move towards a ______ method of production.

Single Team Flow

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Single Piece Flow

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Fluid Flow

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SPC

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Question 31 of 50

31. Question

Which element of waste best describes the unnecessary movement of materials and/or finished goods?

Motion

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Inverntory

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Transport/ Conveyance

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Over Processing

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Question 32 of 50

32. Question

A technique used to dramatically reduce the time to change one tool set-up to another is called ______.

Perfection

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SMED

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Overproduction

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Defect

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Question 33 of 50

33. Question

Which of the following are considered to be the pioneers and “fathers” of Quality Improvement and Statistical Process Control methods?

Steve Jobs, Bill Gates

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Richard Branson, Alan Sugar

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Joseph Juran, W. Edwards Deming, Walter Shewhart

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Jack Welch, Sam Walton

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Question 34 of 50

34. Question

Which of the following is the 4th phase in the DMAIC methodology?

Implement

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Investigate

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Improve

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Determine

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Question 35 of 50

35. Question

Which DMAIC phase has the following objectives?

To understand the current ‘As-Is’ state of the process.
Measurement and data collection related to the problem or opportunity.

Measure

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Define

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Improve

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Analyse

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Question 36 of 50

36. Question

Which of the following best describes the role of a Yellow Belt in a Lean Six Sigma project?

Yellow Belts set the long-term strategies for business improvement.

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Yellow Belts are team members who can identify waste and quality problems and work in teams to improve processes.

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Yellow Belts are Lean and Six Sigma project leaders.

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Yellow Belts are responsible for project selection and review.

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Question 37 of 50

37. Question

Which of the following pairs of DMAIC Phases involves development or use of a “Control Plan?”

Improve and Control

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Define and Control

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Measure and Analyze

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Analyze and Improve

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Question 38 of 50

38. Question

Which of the following is a characteristic of ‘PULL’ in a business process?

Production is achieved according to a well understood schedule

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Production is driven by supplier demand

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Production is driven by production target

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Production is driven by customer demand

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Question 39 of 50

39. Question

Which one of the following best describes Kaizen?

Only useful in manufacturing and supply

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A three-bin system using cards to pull inventory

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The commitment to continuously improve the workplace and our work processes

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A model describing how a process works over time

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Question 40 of 50

40. Question

With reference to the principles of Lean and Six Sigma which one of the following is true?

When you think you know a root cause of a problem then you should immediately change the process to fix it.

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Specialists (such as Black Belts) are the best people to identify waste and problems with work processes.

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All good ideas come from senior management and executives.

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The workers at 'The Gemba' are needed to identify waste and process problems and their ideas and suggestions are very important.

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Question 41 of 50

41. Question

Which of the following is the BEST definition of “Lean Thinking?”

Focus on reducing non-value-added (NVA) time and activities from the value stream.

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Reduce the cost of workers by reducing head-count.

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Reduce variation wherever possible in a process.

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More 'command and control' of workers by upper management.

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Question 42 of 50

42. Question

Which one of the following statements concerning DMAIC is most accurate?

DMAIC is an acronym that stands for DESIGN, MEASURE, ANALYZE, IMPLEMENT, CONTROL

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DMAIC is always used in Lean Six Sigma when conducting Kaizen Events

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DMAIC is a Lean Six Sigma methodology used to improve an existing process when the root causes of the problems are not well understood

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DMAIC is a licensed product for which a fee must be paid to use it

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Question 43 of 50

43. Question

Critical to Quality (CTQ) or Critical to Satisfaction (CTS) characteristics of a product or service usually fall into which of the following categories?

Taste, Texture, Variety

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Functionality, Features, Price, Availability and Delivery Time, Quality

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Weight, Length, Strength

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Satisfaction and Dissatisfaction

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Question 44 of 50

44. Question

Which one of the following categories of waste is related to an over-complicated process with unnecessary process steps (activities)?

Over-processing (Non-Essential Processing)

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Over-Rated

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Defects/ Rework/ Scrap

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Over-Production

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Question 45 of 50

45. Question

What is the main role of the Define phase?

To define solutions

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To define process control methods

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To define root causes of problems

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To define the problem and its impact on the customer

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Question 46 of 50

46. Question

Which of these tools is used to understand and categorize customer requirements?

KANO Diagram

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Pareto Chart

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Gantt Chart

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All of the above

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Question 47 of 50

47. Question

What is the Lean Principle action in the 5S approach, that deals with having those items needed regularly at hand and those items needed less regularly stored out of the way?

Standardizing

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Sorting

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Shining

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Sustaining

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Question 48 of 50

48. Question

A Kanban is used as a signal for the movement of raw materials, parts, or finished goods. In which direction does a Kanban signal typically move?

It moves from the Supplier to the Customer

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It moves in the same direction as the Process Flow

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It moves to the Supplier of the materials, parts, or finished goods

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It moves towards the customer of the process

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Question 49 of 50

49. Question

How does Single Minute Exchange of Dies (SMED) achieve waste reduction in a Lean Process?

Separation of 'Internal and External' activities to reduce the waste of waiting

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Reduction of motion during a change over

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Poka Yoke devices to prevent mistakes being made

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All of the above

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Question 50 of 50

50. Question

What is the name currently used for a ‘best in class’ maintenance program that involves all workers and operators?

Total Quality Management

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Total Productive Maintenance

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Total Corrective Maintenance

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Total Preventative Maintenance

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