1h30p
QUESTION 1
During which phase of DMAIC is a SIPOC usually applied according to Theisens?
A Impro
ve
b Contr
ol
c Analy
sis
D Defin
e
QUESTION 2
1. In the context of lean, the company plans to introduce self-managing teams. Given is an
assembly line with the following 5 operations and capacities per employee.
● Operation 1: 20 units per hour per employee
● Operation 2: 40 units per hour per employee
● Operation 3: 12 units per hour per employee
● Operation 4: 16 units per hour per employee
● Operation 5: 20 units per hour per employee
An LSS GB wants to apply line balancing to achieve maximum flow and resource efficiency.
Several employees (also part-time) can be deployed for one operation. It may also happen that
an employee performs multiple operations.
How many employees are at least needed in the self-managing team if the takt time is 2
minutes?
The basic principle is that every employee can perform all operations.
Round to the nearest whole number.
Total processing time
= (60/20) +(60/40) +(60/12) +(60/16) +(60/20)
=16,25 = sum of cycle time
Number of resource = Sum of cycle time/ Task time = 16,25/2 = 8
employee
10 points
QUESTION 3
1. At which station is the bottleneck?
Lathe
Robot
Assembly
Package
10 points
QUESTION 4
1. A factory works for 480 minutes every day (excluding maintenance and breakdowns). When
production planning, they take into account a downtime of 30 minutes per day due to
disruptions and planned maintenance. The machine runs for a total of 450 minutes.
, The factory produces three products with the following forecast average daily demand: 9 A's,
6 B's, and 3 C's. The processing time for each product is 15 minutes and the setup time for the
start of each batch is unknown. These are the same for all products A, B and C. So a new setup
is required to start each batch. You can assume that the batch of a product can be finished the
next day without any additional setup.
What is the setup time per batch in hours for an EPE of 4 days?
Capacity of machine (total available working time) = 450 minutes 20 points
Processing time a day for 3 products = 15*(9+6+3) = 270 min QUESTION 5
The remaining time = 450-270 = 180 m 1. It is stated
The set-up time for 4 products = EPE *Remaining time = 4 days * 180 = that when
720m
The set-up time for 1 product = 720/3=240m ====240/60 = 4 hours
manufacturing a toaster, 20 possible defects can occur per product. 2500 toasters were
produced. 50 defects were found during the inspections of the toasters.
Calculate DPU to two decimal places (e.g., 0.43). 0.02
DPU = Amount of Defects/ Number of Units
= 50/2500 = 0,02
10 points
QUESTION 6
1. A Sperta service technician receives electric bicycles from dealers every day that need to be
repaired. It is given that an electric bicycle can have 100 possible defects. The number of
opportunities is therefore 100 per product.
He discovered yesterday that 8 out of 10 bicycles had 1 or more faults. So 2 electric bicycles
were correct. A total of 20 defects were found.
Calculate the DPMO.
20,000 (use the comma)
DPMO = (Number of defects*1,000,000)/ (Opportunities*Number of Units)
Number of units = 10
10 points
QUESTION 7
1. Which of the following best describes the difference between ppm and DPMO?
DPMO assumes that each part/process can have only one defect possibility unlike ppm where
each unit can have multiple defects.
PPM considers the defective unit as a whole, while DPMO refers to multiple opportunities per
part / process.
Opportunite in the object and area
Ppm is determined by dividing the number of defective units by the number of non-defective
units.
DPMO ignores the number of "defective opportunities" per product, while ppm distinguishes
between products with many "defective opportunities" and those with few "defective
opportunities".
10 points
QUESTION 8
QUESTION 1
During which phase of DMAIC is a SIPOC usually applied according to Theisens?
A Impro
ve
b Contr
ol
c Analy
sis
D Defin
e
QUESTION 2
1. In the context of lean, the company plans to introduce self-managing teams. Given is an
assembly line with the following 5 operations and capacities per employee.
● Operation 1: 20 units per hour per employee
● Operation 2: 40 units per hour per employee
● Operation 3: 12 units per hour per employee
● Operation 4: 16 units per hour per employee
● Operation 5: 20 units per hour per employee
An LSS GB wants to apply line balancing to achieve maximum flow and resource efficiency.
Several employees (also part-time) can be deployed for one operation. It may also happen that
an employee performs multiple operations.
How many employees are at least needed in the self-managing team if the takt time is 2
minutes?
The basic principle is that every employee can perform all operations.
Round to the nearest whole number.
Total processing time
= (60/20) +(60/40) +(60/12) +(60/16) +(60/20)
=16,25 = sum of cycle time
Number of resource = Sum of cycle time/ Task time = 16,25/2 = 8
employee
10 points
QUESTION 3
1. At which station is the bottleneck?
Lathe
Robot
Assembly
Package
10 points
QUESTION 4
1. A factory works for 480 minutes every day (excluding maintenance and breakdowns). When
production planning, they take into account a downtime of 30 minutes per day due to
disruptions and planned maintenance. The machine runs for a total of 450 minutes.
, The factory produces three products with the following forecast average daily demand: 9 A's,
6 B's, and 3 C's. The processing time for each product is 15 minutes and the setup time for the
start of each batch is unknown. These are the same for all products A, B and C. So a new setup
is required to start each batch. You can assume that the batch of a product can be finished the
next day without any additional setup.
What is the setup time per batch in hours for an EPE of 4 days?
Capacity of machine (total available working time) = 450 minutes 20 points
Processing time a day for 3 products = 15*(9+6+3) = 270 min QUESTION 5
The remaining time = 450-270 = 180 m 1. It is stated
The set-up time for 4 products = EPE *Remaining time = 4 days * 180 = that when
720m
The set-up time for 1 product = 720/3=240m ====240/60 = 4 hours
manufacturing a toaster, 20 possible defects can occur per product. 2500 toasters were
produced. 50 defects were found during the inspections of the toasters.
Calculate DPU to two decimal places (e.g., 0.43). 0.02
DPU = Amount of Defects/ Number of Units
= 50/2500 = 0,02
10 points
QUESTION 6
1. A Sperta service technician receives electric bicycles from dealers every day that need to be
repaired. It is given that an electric bicycle can have 100 possible defects. The number of
opportunities is therefore 100 per product.
He discovered yesterday that 8 out of 10 bicycles had 1 or more faults. So 2 electric bicycles
were correct. A total of 20 defects were found.
Calculate the DPMO.
20,000 (use the comma)
DPMO = (Number of defects*1,000,000)/ (Opportunities*Number of Units)
Number of units = 10
10 points
QUESTION 7
1. Which of the following best describes the difference between ppm and DPMO?
DPMO assumes that each part/process can have only one defect possibility unlike ppm where
each unit can have multiple defects.
PPM considers the defective unit as a whole, while DPMO refers to multiple opportunities per
part / process.
Opportunite in the object and area
Ppm is determined by dividing the number of defective units by the number of non-defective
units.
DPMO ignores the number of "defective opportunities" per product, while ppm distinguishes
between products with many "defective opportunities" and those with few "defective
opportunities".
10 points
QUESTION 8
