LEAN SIX SIGMA UPDATED 2026 EXAMS SCRIPT
QUESTIONS AND ANSWERS GRADED A+
✔✔Key principles of Six Sigma - ✔✔Rigorous methodology for the continuous
improvement of all business processes
Three keys:
1. Processes
2. Variation
3. Customer
✔✔Six Sigma and the Customer - ✔✔Only the customer can establish the
requirements, what is considered a defect, and decide whether product or service is
acceptable or not
✔✔The Six Sigma Objective - ✔✔Reduce variation and center the process on the peak
of the Gaussian curve
✔✔Process Improvements - ✔✔Inputs: measure inputs and outputs and identify
variation
Process: implement solutions to reduce variation in process
Output: control revised process
✔✔What is sigma level? - ✔✔The sigma level defines its capability to operate within
specifications without defects (i.e. the number of standard deviations that fit between
the mean and upper and lower specifications)
✔✔Six Sigma Long Term Process Availability - ✔✔A six sigma process operates within
specifications in 99.9997% of the instances near perfection
✔✔Two Methodologies of Six Sigma - ✔✔DMAIC (Define, Measure, Analyze, Improve,
Control)
DFSS (Design For Six Sigma)
✔✔DMAIC - ✔✔1.Define (customer's needs and improvement obj.)
2.Measure (determine process performance and capability to customer needs)
3. Analyze (identify key process performance drivers in data)
4. Improve (statistically validate improvement opportunities)
5. Control (set appropriate controls to ensure improvements' sustainability)
✔✔DEFINE Phase Toolkit - ✔✔Project Charter, Stakeholder Analysis, SIPOC, Rolled
Throughput Yield, VOC, Affinity Diagram, Kano Model, CTQ, Benchmarking
✔✔Rolled Throughput Yield - ✔✔The product of the yields of each of the steps in the
process
, ✔✔Kano Model - ✔✔1. Dissatisfiers/BASIC requirements-(Requirements that customer
absolutely expect to be met)
2. Satisfiers/Variable Requirements-(have a linear effect of customer satisfaction, the
more you have the more competitive you are)
3. Delighters/Latent Requirements-(go beyond what the customer expects
✔✔CTQ Tree - ✔✔Tool that helps translate customer language into qualified
requirements for a product or service
✔✔Benchmarking - ✔✔A process of measuring a company's process and
product/service performance against those companies that consistently distinguish
themselves in the same category of performance
✔✔Failure Models and Effects Analysis - ✔✔1. Identify the process or product/service
2. List the potential problems that could arise (Failure Modes)
3. Rate the problem for severity (s), probability of occurrence (o), and probability of
failure to detect (D)
4. Calculate the Risk Priority Number (RPN) and prioritize based on highest RPN
RPN=S x O x D
5. Develop actions plans to reduce risk
✔✔Statistical Process Control - ✔✔The measurement of variation in a process
-identify "out of control' conditions
-evaluate process changes
-ongoing alarm systems
Control=operating w/in a specific range of upper and lower control limits (UCL & LCL)
✔✔Control Chart - ✔✔UCL=above mean
LCL=below mean
Defects occur below LCL
✔✔Process Sigma - ✔✔Very sensitive indicator
Focuses on defects
Distribution shift +/- 1.5 sigma
-Low=93%; DPMO=66,807; Sigma=3.0
-High=99.9997%
DPMO=3.4
Sigma=6.0
✔✔Pareto Charts - ✔✔*Limited number of people control the wealth*
Pareto-Lorenz maldistribution law: Cause and Effect not linearly related-<=20% of
causes produce >=80% of effects
✔✔Brainstorming - ✔✔1.Two Techs:
Rounds (go around in turns with one item per person until done)
QUESTIONS AND ANSWERS GRADED A+
✔✔Key principles of Six Sigma - ✔✔Rigorous methodology for the continuous
improvement of all business processes
Three keys:
1. Processes
2. Variation
3. Customer
✔✔Six Sigma and the Customer - ✔✔Only the customer can establish the
requirements, what is considered a defect, and decide whether product or service is
acceptable or not
✔✔The Six Sigma Objective - ✔✔Reduce variation and center the process on the peak
of the Gaussian curve
✔✔Process Improvements - ✔✔Inputs: measure inputs and outputs and identify
variation
Process: implement solutions to reduce variation in process
Output: control revised process
✔✔What is sigma level? - ✔✔The sigma level defines its capability to operate within
specifications without defects (i.e. the number of standard deviations that fit between
the mean and upper and lower specifications)
✔✔Six Sigma Long Term Process Availability - ✔✔A six sigma process operates within
specifications in 99.9997% of the instances near perfection
✔✔Two Methodologies of Six Sigma - ✔✔DMAIC (Define, Measure, Analyze, Improve,
Control)
DFSS (Design For Six Sigma)
✔✔DMAIC - ✔✔1.Define (customer's needs and improvement obj.)
2.Measure (determine process performance and capability to customer needs)
3. Analyze (identify key process performance drivers in data)
4. Improve (statistically validate improvement opportunities)
5. Control (set appropriate controls to ensure improvements' sustainability)
✔✔DEFINE Phase Toolkit - ✔✔Project Charter, Stakeholder Analysis, SIPOC, Rolled
Throughput Yield, VOC, Affinity Diagram, Kano Model, CTQ, Benchmarking
✔✔Rolled Throughput Yield - ✔✔The product of the yields of each of the steps in the
process
, ✔✔Kano Model - ✔✔1. Dissatisfiers/BASIC requirements-(Requirements that customer
absolutely expect to be met)
2. Satisfiers/Variable Requirements-(have a linear effect of customer satisfaction, the
more you have the more competitive you are)
3. Delighters/Latent Requirements-(go beyond what the customer expects
✔✔CTQ Tree - ✔✔Tool that helps translate customer language into qualified
requirements for a product or service
✔✔Benchmarking - ✔✔A process of measuring a company's process and
product/service performance against those companies that consistently distinguish
themselves in the same category of performance
✔✔Failure Models and Effects Analysis - ✔✔1. Identify the process or product/service
2. List the potential problems that could arise (Failure Modes)
3. Rate the problem for severity (s), probability of occurrence (o), and probability of
failure to detect (D)
4. Calculate the Risk Priority Number (RPN) and prioritize based on highest RPN
RPN=S x O x D
5. Develop actions plans to reduce risk
✔✔Statistical Process Control - ✔✔The measurement of variation in a process
-identify "out of control' conditions
-evaluate process changes
-ongoing alarm systems
Control=operating w/in a specific range of upper and lower control limits (UCL & LCL)
✔✔Control Chart - ✔✔UCL=above mean
LCL=below mean
Defects occur below LCL
✔✔Process Sigma - ✔✔Very sensitive indicator
Focuses on defects
Distribution shift +/- 1.5 sigma
-Low=93%; DPMO=66,807; Sigma=3.0
-High=99.9997%
DPMO=3.4
Sigma=6.0
✔✔Pareto Charts - ✔✔*Limited number of people control the wealth*
Pareto-Lorenz maldistribution law: Cause and Effect not linearly related-<=20% of
causes produce >=80% of effects
✔✔Brainstorming - ✔✔1.Two Techs:
Rounds (go around in turns with one item per person until done)
