Name:

Six Sigma Green Belt Certification Test. Time: 2 hours Marks: 50

The Question paper is given to you in word document as a softcopy. Please enter your name on the Top left hand Corner. The Question paper has 3 sets of Questions. All Questions are Compulsory. Set 1 is Multiple Choice. You need to change the color of the right answer to green and save the file. It has 22 Questions each of 1 mark. There is no negative marking. Set 2 is Short Answers. It has 2 Questions of 6 marks each. You need to insert your answers after each question and save the file. Set 3 is analysis and has 1 Question of 16 marks. You need to insert your answers after the question and save the file. Note please copy analysis / graphs and any other thing that you deem fit from your Minitab analysis, onto this word document to support your answers. Also pen the same in your answers sheets hard copy. Set one needs to be answered on the Question paper itself. Set 1 Multiple Choice 1. A team has been asked to reduce the cycle time for a process. The team decides to collect baseline data. It will do this by A. seeking ideas for improvement from all stakeholders B. researching cycle times for similar processes within the organization C. obtaining accurate cycle times for the process as it currently runs D. benchmarking similar processes outside the organization 2. A Six Sigma project designed to solve a particular problem needs a definition/scope statement to help avoid: A. going beyond the problem into other problems B. failing to cover the entire problem C. misunderstanding and disagreement between team members regarding problem boundaries D. all of the above E. none of the above

3. There are 14 different defects that can occur on a completed time card. The payroll department collects 328 cards and finds a total of 87 defects. Then DPU =_____ A. 87/328 B. 87/(328x14) C. 87/14 D. (87x1,000,000)/(14x328) 4. There are 14 different defects that can occur on a completed time card. The payroll department collects 328 cards and finds a total of 87 defects. Then DPMO =____ A. 87/328 B. 87/(328x14) C. 87/14 D. (87x1,000,000)/(14x328) 5. For a manufacturer making tetrapacks, the customer is willing to accept the product only if it weighs between 490 gms and 510 gms. The machine is able to produce packs with a mean of 500 gms and a standard deviation of 1gm. Which of the following is true A. USL = 506 gms and LSL = 494 gms B. USL = 510 gms and LSL = 490 gms C. USL = 490 gms and LSL = 510 gms D. USL = 497 gms and LSL = 503 gms 6. In Box plot, the inside horizontal line describes the A. mean B. median C. mode

D. none of the above

7. The mean, median and mode of a distribution have the same value. What can be said about the distribution: A. it is exponential B. it is normal C. it is poison D. none of the above(unimodal) 8. For a normal distribution, two standard deviations on each side of the mean would include approx what percentage of the total population? A. 47% B. 68% C. 95% D. 99% E. None of the above 9. In regression analysis. R = 0.88 signifies A. 88% of the variation in X is explained by variation in Y B. 12% of the variation in Y is explained by variation in X C. 12% of the variation in X is explained by variation in Y D. 88% of the variation in Y is explained by variation in X 10. Which is true? A. Cp >= Cpk B. Cp < Cpk the above

C. Cp, Cpk are not comparable

D. none of

11. Which one of the following is true ? A. ZLT = ZST + 1.5 B. ZST = ZLT C. ZST = ZLT + 1.5 D. none of the above 12. Pareto diagram is used: A. To identify vital few from trivial many C. To identify cause and effect relationship B.To calculate mean and s.d. D. none of the above

13. Measurement uncertainty is known and suitable if A. %R&R = 50% B. %R&R <= 10% C. %R&R >30% D. None of the above 14. Variation in a process exists due to A. Chance Causes B. assignable causes C. Chance & assignable causes D. It happens without any causes 15. FMEA stands for A. Failure Mode and Effect Analysis B. Failure Mode and Efficient Analysis C. Failure Model for Effectiveness Analogy D. Fatal modes for Electrical Assemblies. 16. Which of the following are not included in the project charter A. Project scope B. Project goal C. Project title D. Tools to be used 17. CTQs are derived from A. Histogram B. VOC

C. Run chart

D. Pareto diagram

18. There is a group of 10 students in a class. Their weights in kgs are as follows: 20, 22, 30, 30, 30, 45, 50, 56, 56, 60. Which of the following is true? A. Mean is 39.9 kg, Median is 37.5 kg & Mode is 30 kg B. Mean is 37.5 kg, Median is 39.9 kg & Mode is 30 kg C. Mean is 30 kg, Median is 37.5 kg & Mode is 37.5 kg D. Mean is 39.9 kg, Median is 60 kg & Mode is 20 kg 19. The weight of the pouches of a particular product is normally distributed with a mean of 200 kg. We know that 68.26% of the pouches weigh between 196 kg and 204 kg. Which of the following is likely to be the standard deviation of the distribution? A. 8 B. 2 C. 4 D. 5 20. The process capability is defined by the formula A. (Mean-LSL)/(6*) B.(USL-LSL)/(6*) C. (USL-LSL)/() D. (USL-LSL)/(3*) 21. Which of the following is true? A. All the non- value adding activities can be eliminated B. All the processes in the TO BE map should be value-added activities C. All the activities in the TO BE map need not necessarily be value -adding activities D. Delays can always be eliminated 22. Which of the following hold true for Normal Distribution?

A. A normally distributed process has only 0.0000002% parts outside the +/- 6 limits B. Taken along with a long term mean shift of +/- 1.5 it denotes 3.4 ppm or virtually Zero Defect C. It is a Bell shaped Curve D. All of the above Set 2 Short Answers

1 . The Performance output of 4 operators was measured and the same is given below. Check using ANOVA if performance of operators is equal or Not. Operator 1 21.4 23.2 21.5 22.2 Operator 2 22.2 23.1 21.5 22.7 24.8 Operator 3 20.2 22.5 20.7 23.2 Operator 4 23.2 24.1 23.1 23.0

01-09-2013 14:55:16
Welcome to Minitab, press F1 for help. Executing from file: C:\Program Files\Minitab\Minitab 16\English\Macros\Startup.mac This Software was purchased for academic use only. Commercial use of the Software is prohibited.

Gage R&R Study - ANOVA Method

* ERROR * Design is not balanced; execution aborted.

One-way ANOVA: Operator1, Operator 2, Operator3, Operator 4

Source Factor Error Total DF 3 13 16 SS 7.15 15.10 22.25 MS 2.38 1.16 F 2.05 P 0.156

S = 1.078

R-Sq = 32.14%

R-Sq(adj) = 16.47% Individual 95% CIs For Mean Based on Pooled StDev ---------+---------+---------+---------+ (---------*---------) (--------*-------) (--------*---------) (---------*--------) ---------+---------+---------+---------+ 21.6 22.8 24.0 25.2

Level Operator1 Operator 2 Operator3 Operator 4

N 4 5 4 4

Mean 22.075 22.860 21.650 23.350

StDev 0.830 1.238 1.429 0.507

Pooled StDev = 1.078

Individual Value Plot of Operator1, Operator 2, Operator3, Operator 4 Boxplot of Operator1, Operator 2, Operator3, Operator 4 Normplot of Residuals for Operator1, Operator 2, Operator3, Operator 4 Residual Histogram for Operator1, Operator 2, Operator3, Operator 4 One-way ANOVA: Operator1, Operator 2, Operator3, Operator 4
Source Factor Error Total DF 3 13 16 SS 7.15 15.10 22.25 MS 2.38 1.16 F 2.05 P 0.156

S = 1.078

R-Sq = 32.14%

R-Sq(adj) = 16.47% Individual 95% CIs For Mean Based on Pooled StDev ---------+---------+---------+---------+ (---------*---------) (--------*-------) (--------*---------) (---------*--------) ---------+---------+---------+---------+ 21.6 22.8 24.0 25.2

Level Operator1 Operator 2 Operator3 Operator 4

N 4 5 4 4

Mean 22.075 22.860 21.650 23.350

StDev 0.830 1.238 1.429 0.507

Pooled StDev = 1.078

Individual Value Plot of Operator1, Operator 2, Operator3, Operator 4 Boxplot of Operator1, Operator 2, Operator3, Operator 4 Residual Plots for Operator1, Operator 2, Operator3, Operator 4

Normal Probability Plot

(responses are Operator1, Operator 2, Operator3, Operator 4)
99 95 90 80 70 60 50 40 30 20 10 5 1

Percent

-2

-1

0 Residual

Individual Value Plot of Operator1, Operator 2, Operator3, Operator 4

25

24

23

Data
22 21 20 Operator1 Operator 2 Operator3 Operator 4

Boxplot of Operator1, Operator 2, Operator3, Operator 4

25

24

23

Data
22 21 20 Operator1 Operator 2 Operator3 Operator 4

Histogram
(responses are Operator1, Operator 2, Operator3, Operator 4) 5

Frequency

-1.5

-1.0

-0.5

0.0 0.5 Residual

1.0

1.5

2.0

2. Draw a Cause & Effect Diagram using Mintab for the data given in file Cause & Effect Data.xlsx

Cause-and-Effect Diagram
Measurements Material Personnel

Training Scale Age Experience Motivation Courtesy

Technique

Amount

Lighting

Up to date Order

Age

pe m Te

Or The data of Electricity interruptions in given in the file Electricity Interruptions Reasons.xlsx. Which interruptions will you address in priority and why. Draw graphs/ charts where necessary. Set 3 Analysis Analyze the data given in the file Oil Bottle Data.xlsx using Minitab and give your inferences. Stat >BasicStatistics> Normality Test>Select Oil>Ok

id m Hu it y

er pp ra W s xe Bo r te in Pr

Environme nt

r tu ra e
Humidity Power

Consistency Procedure

Cleanliness

Maintence

Methods

Machines

Probability Plot of Oil

Normal
99.9 99 95 90 80 70 60 50 40 30 20 10 5 1 0.1 Mean 220.9 StDev 3.621 N 240 AD 3.322 P-Value <0.005

Percent

210

215

220

225 Oil

230

235

240

Ho: Data is normal P-value is the prob that data is normal We reject Ho when p value is < .05 We reject Ho as p value is <0.005 Hence Data is non normal

Stat>ANOVA>Main Effects Plot>Response:Oil; Factors:Branch, Shift, Study Hour, Employee

Main Effects Plot for Oil
Data Means
Branch 224 222 220 Shift

Mean

Study hour 224 222 220

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5

Employee

10

11

12

Split Worksheet Branchwise

Branch B
Probability Plot of Oil
Normal
99.9 99 95 90 80 70 60 50 40 30 20 10 5 1 0.1 Mean 222.6 StDev 3.591 N 120 AD 2.640 P-Value <0.005

Percent

210

215

220

225 Oil

230

235

Branch A
Probability Plot of Oil
Normal
99.9 99 95 90 80 70 60 50 40 30 20 10 5 1 0.1 Mean StDev N AD P-Value 219.1 2.697 120 1.025 0.010

Percent

210

215

220 Oil

225

230

Since p value is <.05 in both cases hence we reject Ho and conclude data is non normal in both cases Main Effect Plot for Branch A

Main Effects Plot for Oil

Data Means
Shift 220 218 216 Study hour

Mean

214
1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Employee 220 218 216 214

1 2 3 4 5 6 7 8 9 10 11 12

Looks affected by EMPLOYEE 3 BRANCH B

Main Effects Plot for Oil
Data Means
Shift 230.0 227.5 225.0 222.5 220.0 Study hour

Mean

Employee 230.0 227.5 225.0 222.5 220.0

1 2 3 4 5 6 7 8 9 10 11 12

1 2 3 4 5 6 7 8 9 10 11 1 2 1 3 14 1 5 1 6 1 7 18 19 20

\ Looks affected by EMPLOYEE 6 Subset Worksheet of Branch A excluding employee 3 and only employee 3

Branch A excluding employee 3 Normality Test

Probability Plot of Oil
Normal
99.9 99 95 90 80 70 60 50 40 30 20 10 5 1 0.1 Mean StDev N AD P-Value 219.6 2.135 110 0.178 0.917

Percent

212

214

216

218

220 Oil

222

224

226

Subset worksheet of Branch A only employee 3

Probability Plot of Oil
Normal
99 95 90 80 70 60 50 40 30 20 10 5 1 Mean StDev N AD P-Value 214.5 3.856 10 0.247 0.672

Percent

205

210

215 Oil

220

225

Here p value is > 0.05 in both cases hence we fail to reject null hypothesisand conclude data is normal in both cases Process Capability of Branch 1 without Employee 3

Process Capability of Oil

LSL Process Data LSL 210 Target * USL 230 Sample Mean 219.565 Sample N 110 StDev(W ithin) 2.10543 StDev(Overall) 2.1352 USL W ithin Overall Potential (Within) Capability Cp 1.58 CPL 1.51 CPU 1.65 Cpk 1.51 Overall Capability Pp PPL PPU Ppk Cpm 1.56 1.49 1.63 1.49 *

210
Observed Performance PPM < LSL 0.00 PPM > USL 0.00 PPM Total 0.00

213

216

219

222

225

228

Exp. W ithin Performance PPM < LSL 2.77 PPM > USL 0.36 PPM Total 3.13

Exp. Overall Performance PPM < LSL 3.74 PPM > USL 0.51 PPM Total 4.25

Process Capability only Employee 3 Branch A

Process Capability of Oil
LSL Process Data LSL 210 Target * USL 230 Sample Mean 214.505 Sample N 10 StDev(W ithin) 2.5858 StDev(Overall) 3.85554 USL W ithin Overall Potential (Within) Capability Cp 1.29 CPL 0.58 CPU 2.00 Cpk 0.58 Overall Capability Pp PPL PPU Ppk Cpm 0.86 0.39 1.34 0.39 *

208
Observed Performance PPM < LSL 100000.00 PPM > USL 0.00 PPM Total 100000.00

212

216

220

224

228

Exp. W ithin Performance PPM < LSL 40749.37 PPM > USL 0.00 PPM Total 40749.37

Exp. Overall Performance PPM < LSL 121333.91 PPM > USL 29.22 PPM Total 121363.14

WE see that process capability of Branch A excluding employee 3 is far better than that of Branch A Employee 3 only Hence Employee 3 must be fixed (Trained)

Marginal Plot of Oil vs Employee

235 230

Oil

225 220 215 210 0 2 4 6 8 Employee 10 12

Branch B excluding employee 6 and only employee 6 Branch B excluding employee 6 Normality Test
Probability Plot of Oil
Normal
99.9 99 95 90 80 70 60 50 40 30 20 10 5 1 0.1 Mean StDev N AD P-Value 221.9 2.703 110 0.748 0.050

Percent

215

220 Oil

225

230

Only Employee 6

Probability Plot of Oil

Normal
99 95 90 80 70 60 50 40 30 20 10 5 1 Mean StDev N AD P-Value 230.6 2.383 10 0.674 0.054

Percent

225.0

227.5

230.0 Oil

232.5

235.0

237.5

P value is >.05 hence we fail to reject null hypothesis and conclude that data is normal in both the cases Process capability index Without Employee6
Process Capability of Oil
LSL Process Data LSL 210 Target * USL 230 Sample Mean 221.919 Sample N 110 StDev(W ithin) 2.59898 StDev(Overall) 2.70298 USL W ithin Overall Potential (Within) Capability Cp 1.28 CPL 1.53 CPU 1.04 Cpk 1.04 Overall Capability Pp PPL PPU Ppk Cpm 1.23 1.47 1.00 1.00 *

210
Observed Performance PPM < LSL 0.00 PPM > USL 9090.91 PPM Total 9090.91

213

216

219

222

225

228

231

Exp. W ithin Performance PPM < LSL 2.26 PPM > USL 937.87 PPM Total 940.13

Exp. Overall Performance PPM < LSL 5.18 PPM > USL 1396.72 PPM Total 1401.89

Only Employee 6

Process Capability of Oil

LSL Process Data LSL 210 Target * USL 230 Sample Mean 230.578 Sample N 10 StDev(W ithin) 1.86072 StDev(Overall) 2.38343 USL W ithin Overall Potential (Within) Capability Cp 1.79 CPL 3.69 CPU -0.10 Cpk -0.10 Overall Capability Pp 1.40 PPL 2.88 PPU -0.08 Ppk -0.08 Cpm *

212
Observed Performance PPM < LSL 0.00 PPM > USL 400000.00 PPM Total 400000.00

216

220

224

228

232

236

Exp. W ithin Performance PPM < LSL 0.00 PPM > USL 621898.86 PPM Total 621898.86

Exp. Overall Performance PPM < LSL 0.00 PPM > USL 595758.02 PPM Total 595758.02

WE see that process capability of Branch B excluding employee 6 is far better than that of Branch A Employee 6 only Hence Employee 6 must be fixed (Trained)

Marginal Plot
Marginal Plot of Oil vs Employee

235 230

Oil

225 220 215 210 2 4 6 8 Employee 10 12