Lean Six Sigma Green Belt Certification practice test with complete verified solutions 2024 latest update

What is Six Sigma? is both a methodology for process improvement and a statistical concept that seeks to define the variation inherent in any process. The overarching premise of Six Sigma is that variation in a process leads to opportunities for error; opportunities for error then lead to risks for product defects. Brainpower Read More 0:01 / 0:15 Decision-making with Six Sigma The six sigma method lets organizations identify problems, validate assumptions, brainstorm solutions, and plan for implementation to avoid unintended consequences. What is 6σ as a statistical concept? is a statistical representation of what many experts call a "perfect" process. Technically, in a six sigma process, there are only 3.4 defects/1,000,000 opportunities, or 99.99966% of the products from six sigma are without defect. Common six sigma principles - Customer-focused improvement - Value streams - Continuous process improvement - Variation - Removing waste - Equipping people - Controlling the process Value stream is the sequence of all items, events, and people required to produce an end result Jidoka a principle that creates control of defects inside a business. Jidoka demands that a process stop as soon as errors are detected instead of identifying defects at the end of the production line and attempting to trace errors back to a source. Principles of Lean Six Sigma - Defining customer values - Identifying the value stream for customer needs and desires - Identifying waste in the process - Creation of a continuous process flow - Continually working to reduce the number of steps and time it takes to reach customer satisfaction Rummler-Brache's Nine Box Model - Improvement-planning - Definition - Analysis and Design - Implementation - Management of process - Processes are turned over to daily teams Scrum is a project development method specific to Agile programming endeavors in technical departments. When to use six sigma - When facing the unknown - When problems are widespread and not defined - When solving complex problems - When costs are closely tied to processes Other formal quality or process improvement programs - Lean Process Management - Total Quality Management - Business Process Reengineering - Rummler-Brache - Scrum - The Customer Experience Management Method - JumpStart Muda Waste that fails to add value to a product or process as defined by the customer or end-user. The Seven Muda or Wastes - Overproduction - Correction - Inventory - Motion - Conveyance - Over-processing - Waiting Muda of Overproduction A product, part, or service was produced too fast, at the wrong time, or in too much quantity for the process. Muda of Correction Reworking an end product to eliminate defects. Muda of Inventory When materials or inputs stack up before a step in the process. Muda of Motion How employees themselves move during a process. E.g: The half a second it takes for data entry employees to toggle between two windows could cost the company x amount of dollars depending on salary. Muda of Conveyance Involves the movement of outputs, products, or resources. E.g: If the glue that binds doll eyes to doll faces is kept in an inventory room, and carried, as needed, to the process. Muda of Overprocessing When an employee or process inputs more resources into a product or services than is valued by the customer. E.g: When an office worker delves deep into insurance verification, spending an hour on the phone with the company to get detailed benefit information. Muda of waiting Refers to any idle time in a process, whether that time is for machinery or for people. Other forms of waste - Talent - Ideas - Capital/Cash Type I Muda Non-value added tasks that might actually be essential or required by circumstances E.g: Inspection of products during a process if the process is known to produce defects. Type II Muda Non-value added tasks that are not essential and can be immediately removed from a process. 5S a Japanese Lean approach to organizing a workspace, so that by making a process more effective and efficient, it will become easier to identify and expunge muda. 5S Steps: Phase I: Sort All items are reviewed, removing unneeded items, and keeping necessary resources. 5S Steps Phase II: Straighten Every item, tool, or material is given a streamlined and easy-to-use/access location 5S Steps Phase III: Shine Clean, maintain, and return items to their proper place. 5S Steps Phase IV: Standardize Used to maintain the progress achieved in all other phases. 5S Steps Phase V: Sustain Follow all the rules set by the other phases. Just-in-time Manufacturing another Lean concept that originated with Totoya. It means to produce an output just in time or as needed by the customer. E.g: Companies attempt to estimate how many of each product will sell before they produce those products. OR, one machine does not out-produce another if they are co-dependent. Standard deviation Measures the distance between data points and the mean of all the data. -Large SD: overall wide spread of points -Small SD: closely clustered set of points Variance Standard deviation squared Why calculate standard deviation? It gives you an idea of how much variation actually exists in a process while taking outliers somewhat into account. The Pareto Principle (80/20 Rule) Says that 20% of the causes lead to 80% of the effects. Or, the vital few inputs drive the majority of the outputs. Pareto Chart A graphical representation of data elements - usually inputs or causes - in a ranked bar chart. Those bars are arranged in order of height, with the highest on the left and the lowest on the right. General customer feedback Often obtained through feedback forms, customer complaint records, and passive information gathering via websites or social media. -General Voice of Customer (VOC) feedback is used a smoke alarm. The 5 Whys a brainstorming tool that asks increasingly granular why questions about a problem or process, seeking to understand the actual root or cause of the problem. A strong problem statement covers - When? - Where? - What? - How many? - What is the magnitude? Process A collection of tasks, steps, or activities that are performed, usually in a specific order, and result in an end product such as a tangible good or provision of a service. 4 Layers of the Process - The steps - Processing time - Interdependencies - Resources and assignment