After the successful completion and implementation of the first four phases of DMAIC, the control phase should be completed by which of the following?

1. The black belt alone; the project has been successfully completed
2. The process owner alone; it is his/her responsibility to take the project from here
3. The process owner and black belt together
4. The complete team is the most desirable option

d

Process A consists of several machines that combine their output into a common stream. Once combined, it is impossible to trace single pieces to specific machines. Process B receives the mixed pieces. A corrective action requires finding the root cause of a defect found in some of these pieces. A team assigned to this problem is thinking of using SQC to detect the source of the problem. Where should SQC be implemented?

1. At the beginning of Process B
2. At each machine in Process A
3. At the end of Process B
4. At the beginning of Process A

b

Which of the following would be a device associated with the visual factory?

1. Standard work
2. Andon board
3. Queue time
4. Work cell

b

Advantages of control charts include:

1. They can detect trends of statistical significance
2. They provide straightforward, easily interpreted information
3. They can immediately identify good processes
4. They can detect when employees are pencil-whipping the data

a

Control limits are set at the 3 sigma level because:

1. This level makes it difficult for the output to get out of control
2. This level establishes tight limits for the production process
3. This level reduces the probability of looking for trouble in the process when none exists
4. This level assures a very small type II error

b

A process is checked by inspection of random samples of four shafts after a polishing operation, and X-bar and R charts are maintained. A person making a spot check picks out two shafts, measures them accurately, and plots the average value on the X-bar chart. The point falls just outside the control limits. The department foreman is advised to stop the process. This decision indicates that:

1. The process level is out of control
2. Both the level and dispersion are out of control
3. The process level is out of control but not the dispersion
4. The person is not using the chart correctly

d

The factor D_4 in X-bar and R control charts is used to:

1. Determine the upper control limit of a range chart
2. Establish the control limits for the average chart
3. Correct the bias in estimating the population
4. Determine the lower control limit of a range chart

a

What is the importance of the reaction plan in a control plan?

1. It describes what will happen if a key variable goes out of control
2. It indicates that a new team must be formed to react to a a problem
3. It lists how often the process should be monitored
4. It defines the special characteristics to be monitored

a

The control chart that is most sensitive to variations in a measurement is:

1. p chart
2. np chart
3. c chart
4. X-bar and R chart

d

After the successful implementation of an "improve" stage, a DMAIC team is considering control charts to monitor the new gains for a process. Which approach would provide the best results?

1. Chart as many characteristics as possible
2. Chart the most important input variables associated to the CTQs
3. Use control charts for variables only
4. Use numerous control charts for attributes and variables

b

Which control chart pattern best represents an in control process?

1. A consecutive run of seven or more points on one side of the centerline
2. A random distribution of points with one point outside the control limits
3. A random distribution of points on both sides of the centerline
4. A steady trend of points toward either control limit

c

An R chart is generally used to:

1. Determine if the process is in control
2. Determine if the process mean is in control
3. Determine if the process variance is in control
4. Determine the variance of the process

c

The single most important factor in establishing an effective company training effort is:

1. Top management support
2. Willingness of an employee to learn
3. Immediate supervisor's support
4. Good instruction and materials

a