Six Sigma Exam 1 with Questions and
Correct Answers 2025
Lean Intro - CORRECT ANSWERS - Starting 1910's, Henry Ford's mass
production line
was a first breakthrough by using continuous assembly and flow systems
that made parts find their way into finished products
- Inception in 1940's by Toyota
- Taichii Ohno and Shigeo Shingo created a new
system called Toyota Production System (TPS),
incorporating Ford production and other techniques
- In 1990, the term "Lean Manufacturing" first appeared in the book "The
Machine That Changed The World"
Motorola - CORRECT ANSWERS - Motorola 1979 "The real problem at
Motorola is that our quality stinks!"
--- Art Sundry, Sales Leader, boldly stated at annual sales meeting
- In the early and mid-1980's, Motorola developed the new standard and
created the methodology
--- $20MM in savings for Motorola's page production line
--- Also a change in mindset (Cost of Poor Quality) and culture
who founded the six sigma academy and when - CORRECT ANSWERS mid
1980's, Mikel Harry & Richard Schroeder founded the Six Sigma
Academy
When did six sigma become famous? - CORRECT ANSWERS Six Sigma
became famous when Jack Welch made it central to his successful business
strategy at General Electric in 1995
- Reported $200MM in savings in the first year of implementation (1996)
Why Lean and Six Sigma? - CORRECT ANSWERS • They are not only tools or
methodologies
• More importantly, they are mindsets!
• Why do you want to learn about it?
• Lean and Six Sigma complement each other
- Lean focuses on eliminating wastes and improving efficiency
- Six Sigma focuses on reducing defects and variation
**Lean + Six Sigma Faster (speed) & Better (accuracy)**
,Impact on Suppliers - CORRECT ANSWERS - Lower costs due to efficient
systems
- Shorter lead times
- Lower safety stock
impact on operations - CORRECT ANSWERS - Proper cycle time calculation
ensures. production according to
customer demand
- Uniform work flow
- Pull production
impact on logistics - CORRECT ANSWERS - Optimization models to select
routes
- Warehouse design changes reduce waste
Lean Six Sigma In a Nutshell - CORRECT ANSWERS • If you want to achieve
your goals, don't
focus on them.
- Reggie Rivers @ TED Talk
• Instead, focus on your behaviors, or things
that you can control.
Both lean and six sigma are applied throughout the
____________ system - CORRECT ANSWERS Both lean and six sigma are
applied throughout the
manufacturing system
- Production
- Order fulfillment
- Inventory
- Cycle time
- Service delivery
- Etc.
solutions/causes matrix - CORRECT ANSWERS Solutions
Simple Complex
Causes
Known Just Do It Lean
Unknown Ask an Expert Six Sigma
Lean is to: - CORRECT ANSWERS to reduce the waste (non-value added)
time
Reducing wastes consequently results in: - CORRECT ANSWERS -reduced
cycle times
-greater throughout
-better productivity
, -improved quality
-reduced costs
**All of these improve customer satisfaction and the company's competitive
advantage**
5 Lean Thinking Fundamentals - CORRECT ANSWERS 1. Specify VALUE
(Value is defined by customers in terms of specific products and services)
2. create a VALUE STREAM
(Map all steps that bring a product or service to the customers to identify and
eliminate wastes)
3. Establish FLOW
(the continuous movement of products, services and information down the
value stream)
4. Implement PULL
(nothing is done by the upstream process until the downstream customer
signals the need)
5. Work for PERFECTION
(Pursue continuous improvement again and again)
Value - CORRECT ANSWERS -the inherent worth of a product as JUDGED BY
THE CUSTOMER and reflected in its selling price and market demand
-simply, what the customer is willing to pay for
value added process - CORRECT ANSWERS a process step that transforms
or shapes a product or service which is eventually sold to a customer. Value
is defined as anything the customer will pay for.
Non-Value Added Process - CORRECT ANSWERS process steps that take
time, resources, or space, but do not add value to the product or service
Muda - CORRECT ANSWERS Japanese word for waste
Waste - CORRECT ANSWERS -any activity that absorbs resources, and
hence adds costs and time, but adds no value to customers
--Customers only pay for value added activities
-Waste is a symptom
--Minimizes necessary wastes (project coordination, practicing law and
company regulation, etc.)
--Eliminate pure wastes (8 typical wastes)
-Typically, 1-10% of activities are value added
8 Wastes (TIMWOOD-T) - CORRECT ANSWERS 1. Transportation
2. Inventory
3. Motion
4. Waiting
5. Over-production
Correct Answers 2025
Lean Intro - CORRECT ANSWERS - Starting 1910's, Henry Ford's mass
production line
was a first breakthrough by using continuous assembly and flow systems
that made parts find their way into finished products
- Inception in 1940's by Toyota
- Taichii Ohno and Shigeo Shingo created a new
system called Toyota Production System (TPS),
incorporating Ford production and other techniques
- In 1990, the term "Lean Manufacturing" first appeared in the book "The
Machine That Changed The World"
Motorola - CORRECT ANSWERS - Motorola 1979 "The real problem at
Motorola is that our quality stinks!"
--- Art Sundry, Sales Leader, boldly stated at annual sales meeting
- In the early and mid-1980's, Motorola developed the new standard and
created the methodology
--- $20MM in savings for Motorola's page production line
--- Also a change in mindset (Cost of Poor Quality) and culture
who founded the six sigma academy and when - CORRECT ANSWERS mid
1980's, Mikel Harry & Richard Schroeder founded the Six Sigma
Academy
When did six sigma become famous? - CORRECT ANSWERS Six Sigma
became famous when Jack Welch made it central to his successful business
strategy at General Electric in 1995
- Reported $200MM in savings in the first year of implementation (1996)
Why Lean and Six Sigma? - CORRECT ANSWERS • They are not only tools or
methodologies
• More importantly, they are mindsets!
• Why do you want to learn about it?
• Lean and Six Sigma complement each other
- Lean focuses on eliminating wastes and improving efficiency
- Six Sigma focuses on reducing defects and variation
**Lean + Six Sigma Faster (speed) & Better (accuracy)**
,Impact on Suppliers - CORRECT ANSWERS - Lower costs due to efficient
systems
- Shorter lead times
- Lower safety stock
impact on operations - CORRECT ANSWERS - Proper cycle time calculation
ensures. production according to
customer demand
- Uniform work flow
- Pull production
impact on logistics - CORRECT ANSWERS - Optimization models to select
routes
- Warehouse design changes reduce waste
Lean Six Sigma In a Nutshell - CORRECT ANSWERS • If you want to achieve
your goals, don't
focus on them.
- Reggie Rivers @ TED Talk
• Instead, focus on your behaviors, or things
that you can control.
Both lean and six sigma are applied throughout the
____________ system - CORRECT ANSWERS Both lean and six sigma are
applied throughout the
manufacturing system
- Production
- Order fulfillment
- Inventory
- Cycle time
- Service delivery
- Etc.
solutions/causes matrix - CORRECT ANSWERS Solutions
Simple Complex
Causes
Known Just Do It Lean
Unknown Ask an Expert Six Sigma
Lean is to: - CORRECT ANSWERS to reduce the waste (non-value added)
time
Reducing wastes consequently results in: - CORRECT ANSWERS -reduced
cycle times
-greater throughout
-better productivity
, -improved quality
-reduced costs
**All of these improve customer satisfaction and the company's competitive
advantage**
5 Lean Thinking Fundamentals - CORRECT ANSWERS 1. Specify VALUE
(Value is defined by customers in terms of specific products and services)
2. create a VALUE STREAM
(Map all steps that bring a product or service to the customers to identify and
eliminate wastes)
3. Establish FLOW
(the continuous movement of products, services and information down the
value stream)
4. Implement PULL
(nothing is done by the upstream process until the downstream customer
signals the need)
5. Work for PERFECTION
(Pursue continuous improvement again and again)
Value - CORRECT ANSWERS -the inherent worth of a product as JUDGED BY
THE CUSTOMER and reflected in its selling price and market demand
-simply, what the customer is willing to pay for
value added process - CORRECT ANSWERS a process step that transforms
or shapes a product or service which is eventually sold to a customer. Value
is defined as anything the customer will pay for.
Non-Value Added Process - CORRECT ANSWERS process steps that take
time, resources, or space, but do not add value to the product or service
Muda - CORRECT ANSWERS Japanese word for waste
Waste - CORRECT ANSWERS -any activity that absorbs resources, and
hence adds costs and time, but adds no value to customers
--Customers only pay for value added activities
-Waste is a symptom
--Minimizes necessary wastes (project coordination, practicing law and
company regulation, etc.)
--Eliminate pure wastes (8 typical wastes)
-Typically, 1-10% of activities are value added
8 Wastes (TIMWOOD-T) - CORRECT ANSWERS 1. Transportation
2. Inventory
3. Motion
4. Waiting
5. Over-production
