IIBM Institute of Business Management

Six Sigma Green Belt

(MM.100)
Section A - Part One

1 . The primary purpose of a control chart is to_________ a. Set Specifications and tolerances b.
Compare operations. c. Determine the stability of a process. d. Accept or reject a lot of material

Ans c

2 When a control chart is used on a new process, capability can be assessed at which of the
following times? a. Before the chart is first started b. After the first ten points are plotted c.
When the plotted points hug the centerline d. After the process is shown to be in control
Ans B

3 Precision is best described as_______ a. A comparison to a known standard b. The achievement

of expected outgoing quality c. The repeated consistency of results d. The difference between
an average measurement and the actual value
Ans
D

4 The overall ability of two or more operators to obtain consistent results repeatedly when
measuring the same set of parts and using the same measuring equipment is the definition
of________ a. Repeatability b. Precision c. Reproducibility d. Accuracy

A and B

5 Which of the following conditions must be met for a process to be in a state of statistical
control? a. Most of the product out by the process is in specification. b. All subgroup averages and rang
are within control limits. c. All variation has been completely removed d. Previously optimal process
settings are used.

6. Which of the following measures of dispersion is equal to the sum of deviations from the mean squared
divided by the sample size?
a. Range
b. Standard deviation
c. Variance
d. Mode
 A

7. An X and R chart is used to_________

a. Indicate process variation
b. Specify design Limits
c. Interpret costs
d. Identify customer expectations

8. Which of the following is the most useful graphical tool for promoting and understanding the process
of capability?
a. A flowchart
b. A histogram
c. An affinity diagram
d. An Ishikawa diagram

9. The type of chart that presents the value of items in descending order is a________
a. Histogram
b. Pareto chart
c. U chart
d. Cusum chart

10. Measures of which of the following provide attributes data?

a. Temperature in degrees
b. Attendance at meetings
c. Weight in pounds
d. Length in metric units

11. The fraction of nonconforming products is plotted on which of the following types of control chart?
a. P chart
b. U chart
c. Np chart
d. C chart

12. A cause and effect diagram is a useful tool for doing which of the following?
a. Determining the flow of a process
b. Detecting shifts in a process
c. Developing theories based on symptoms
d. Arranging theories by defect count
13. Which of the following statistics would best describe the central tendency of a sample of data?
a. Mode
b. Mean
c. Standard deviation
d. Range

14. Which of the following type of tools or techniques is considered qualitative?

a. Histogram
b. Frequency distributions
c. Pareto chart
d. Process observations

15. Out of the following which technique is most useful in narrowing issues and limiting discussion?
a. Brainstorming
b. Quality function deployment
c. Cause and effect analysis
d. Mutilating

16. In statistics, an estimation error that is persistent or systematic is called_________

a. Bias
b. Sensitivity
c. Random
d. Shift

17. For a normal distribution, two standard deviation on each side of the mean would include what
percentage of the total population_______
a. 47%
b. 68%
c. 95%
d. 99%

18. If a distribution is normal, u=50 s=15, what percentage of data will be less than 30?
a. 59.18%
b. 40.82%
c. 9.18%
d. 1.33%

19. A company is receiving an unusually high number of returns from various customers. The first step in
investigating the problem would be to_______
a. Check the inspection records
b. Establish the correlation of the returns to shipments
c. Brainstorm the potential causes
d. Classify the returns by type and degree of serious

20. Which of the following is the best definition of a flow chart?

a. A diagram used to structure ideas into useful categories
b. An illustration used to analyze variation in a process
c. A picture used to separate steps of a process in sequential order
d. An analytical tool used to clarify opposing aspects of a desired change

21. Which of the following activities would NOT contribute to the effective functioning of a team?
a. Eliminating unnecessary activities
b. Development team performance measures
c. Defining process in detail
d. Monitoring each member’s performance

22. What is the standard deviation of the population-10, 4, 16, 12, 8

a. 4.00
b. 4.47
c. 16.00
d. 20.00

23. Which of the following tools would be most appropriate for collecting data to study the symptoms of
a problem?
a. Check sheet
b. Flow diagram
c. Force-field analysis
d. Activity network diagram

24. Which of the following measures is a sufficient statistic for the parameter u?
a. Median
b. Mid-range
c. Mean
d. Mode

25. Positional, cyclical, and temporal variations are most commonly analyzed in_________
a. SPC charts
b. Multi-vari charts
c. Cause and effect diagram
d. Run charts

26. Which of the following describes the deming method for continuous improvement?
a. Cost of quality analysis
b. Process map
c. Tree Diagram
d. Plan-do-check-act cycle

27. In analysis of variance, which of the following distribution is the basis for determining whether the
variance estimates are all from the same population?
a. Chi square
b. Students
c. Normal
d. F

28. Which of the following statement best describes the set of value of a random variable?
a. It is finite.
b. It is an interval
c. It can be discrete or continuous.
d. It can be tracked by using control charts or scatter plots.

29. Which of the following is the best description of randomization?

a. A technique used to increase the precision of an experiment
b. A means of assuring representative sampling
c. The repetition of an observation or measurement
d. The relationship between two or more variables

30. When the order of items is not important, which of the following method is used to determine the
number of sets and subsets of items?
a. Combination
b. Permutation
c. Factorization
d. Simulation

31. Scatter diagrams are best described as_______

a. Histograms.
b. Correlation analysis.
c. Pareto analysis.
d. Ishikawa diagrams.

32. A __________ is created to determine customers of a specific process.

a. Pareto chart
b. Flow diagram
c. Cause and effect diagram
d. Scatter diagram

33. A production line uses signs at specific points on the line to indicate when components or raw
materials need to be replenished. This practice is an example of________
a. Kanban
b. Poka-yake
c. Checkpoints
d. Hoshin

34. Which of the following is a good tool for planning cycle time reduction and concurrent operations?
a. A timeline
b. A Pareto diagram
c. An X and R chart
d. A PERT chart

35. Attribute and variable data are best described as which of the following?
a. Counted values measured values
b. Counted values visual features
c. Measured values counted values
d. Visual features counted values

36. All of the following are common ways for people to react to conflict Except_________
a. Competing
b. Collaborating
c. Avoiding
d. Sabotaging

37. A quality manager has chosen to survey customer satisfaction by taking samples based on the
categories of frequency of use, categories of use, and demographic. This technique is known as_______
a. Random sampling
b. Data collection
c. Stratification
d. Customer classification

38. Which of the following actions is Not used to reduce process cycle time?
a. Analyzing current processes
b. Reducing queue times
c. Setting priorities
d. Implementing activity-based costing
B

39. A company’s accounts payable department is trying to reduce the time between receipt and payment
of invoices and has recently completed a flowchart. Which of the following tool is the next to be used by
them?
a. Fishbone diagram
b. Scatter diagram
c. Box and whisker plat
d. Histogram

40. In a manufacturing company, the machine shop is what kind of customer in relation to the human
resource department?
a. Intermediate
b. Hidden
c. External
d. Internal

We discovered something amazing: The focus of DFSS and DFLS is our internal products
and processes, whereas the focus of QFD is our customers (especially, end users). One
person suggested we rename QFD to DFCV (design for customer value).

5 What is interrelationship Digraph? Explain it with example.

An interrelationship diagram (ID) shows how different issues are related to one another. It helps
identify which issues are causing problems and which are an outcome of other actions. It also
shows the strength of each influence.
An interrelationship diagram consists of a set of boxes, one representing each issue to be
considered. It is organized in a radial pattern on the page. Connecting lines between the boxes
indicates their relationship. Arrows show direct relationships and distinguish causes from effects.
Interrelationship diagrams can be extremely useful when trying to sort out possible causes of a
specific problem. Although they do not identify detailed reasons for the problem, they do allow
one to analyze broader issues as causes and effects of one another.

How to Create and Use an

Interrelationship Diagram
 Identify the problem. Decide what problem to solve by analyzing its various factors.
Place it in a box at the top of the paper.
 Identify issues. Brainstorm to produce any key issues, ideas, reasons, causes, etc., for the
problem. Place each in a rectangle on the page.
 Connect the issues. Choose any item to start with and compare it to any other. Decide if
the two are related to each other in any way. If they are, identify which is a cause and
which is an effect. Use an arrow pointing from cause to effect to show the relationship.
 Identify intensity. If one item has a particularly strong influence on another make the
arrow darker. If it is a weak relationship, use a dotted line.
 Analyze. Any item with a large number of outgoing arrows is a key cause of the problem.
Any item with many arrows pointing to it is a main outcome.
 Solve the issue. Discuss a way to solve the issue by focusing on the main cause.
3 Find the area under the standard normal curve between +1.50 standard deviations and +2.50
standard deviations.

There are two kinds of normal z-tables around these days. The
most common type gives areas from the middle z=0 to the right
and others give the area from the extreme left to the right.

I will assume first that you have the first type, that reads
from z=0 to the right. I'll explain below what to do if you
have the other type as well as how to find it on a TI-83 or
TI-84 graphing calculator.

= —
AREA BETWEEN z=1.5 & z=2.5 = AREA BETWEEN z=0 & z=2.5 — AREA BETWEEN z=0 &
z=1.5

If you have a table which gives the area between

z=0 and z="whatever",

AREA BETWEEN z=0 and z=2.50 is given in the table as .4938

AREA BETWEEN z=0 and z=1.50 is given in the table as .4332

therefore:

AREA BETWEEN z=1.5 & z=2.5 = .4938 — .4332 = .0606

If you have the other kind of table those values will

be .9938-.9332=.0606, the same answer.

If you have a TI-83 or TI-84 calculator and your teacher will

let you use it,

From the cleared main screen

Press 2ND
Press VARS
Press 3

you will see this on the screen --> invNorm(

after that type 1.5,2.5) so that you see this on the

screen ---> invNorm(1.5,2.5)

4 Define terms related to One-Way ANOVA and interpret their results & data plots

The one-way analysis of variance (ANOVA) is used to determine whether the mean of a
dependent variable is the same in two or more unrelated, independent groups. However,
it is typically only used when you have three or more independent, unrelated groups,
 since an independent-samples t-test is more commonly used when you have just two
groups.

5. Define & describe the use of Rational Sub grouping ?

Rational subgrouping is the process of organizing data into groups of items that were
produced under similar conditions in order to measure the variation between
the subgroups instead of between individual data points.

Section C: Applied Theory (30 Marks)

1 Suppose you are cooking steak for 100 people, & the current approval rating is 75%
acceptable. You want to know the affect of different methods and approaches to see how the
overall approval or “yield” is affected. By using the Full Factorial method explain how the overall
approval or “yield” is affected

2 Interpret Control Charts? Distinguish between common & special causes using rules for
determining stastical control.

The focus for this month is on interpreting control charts. Processes, whether manufacturing or
service in nature, are variable. You will not always get the same result each time. The reason for this
is that there are sources of variation in all processes.

There are two major sources of variation (see January 2004 e-zine, available on the website). One is
common cause variation, which is the inherent variation in the process due to the way it was
designed and is managed. It can be reduced only by fundamentally changing the process. This is
usually management's responsibility. There will always be common cause variation present in a
process.

The second type of variation is special cause variation, which is caused by things that don't normally
happen in the process. Employees closest to the process have the responsibility for finding and
removing (if possible) special causes of variation.

A process is in statistical control if only common cause variation is present. How do we know if only
common cause variation is present or if there are also special causes of variation present? The only
way to determine this is through the use of a control chart.
"IN CONTROL" CONTROL CHART

A control chart represents a picture of

a process over time. To effectively use control charts, one must be able to interpret the picture. What
is this control chart telling me about my process? Is this picture telling me that everything is all right
and I can relax? Is this picture telling me that something is wrong and I should get up and find out
what has happened? A control chart tells you if your process is in statistical control. The chart above
is an example of a stable (in statistical control) process.

This pattern is typical of processes that are stable. Three characteristics of a process that is in
control are:

 Most points are near the average

 A few points are near the control limits
 No points are beyond the control limits

If a control chart does not look similar to the one above, there is probably a special cause present.
Various tests for determining if a special cause is present are given below.

POINTS BEYOND THE CONTROL LIMITS

A special cause is present in the process if any points fall above the upper control limit or below the
lower control limit. Action should be taken to find the special cause and permanently remove it from
the process. If there is a point beyond the control limits, there is no need to apply the other tests for
out of control situations. Points on the control limits are not considered to be out of statistical control.