Master Black Belt Practice Test - 2010

The correct answer is "Sort, Set in Order, Standardize, Sustain, Sweep". This answer aligns with the concept of the 5 S's, which is an improvement tool used to create an organized and efficient workplace. The 5 S's stand for Sort (removing unnecessary items), Set in Order (arranging necessary items), Standardize (establishing guidelines and procedures), Sustain (maintaining the improvements), and Sweep (keeping the workplace clean). This sequence of actions helps to eliminate waste, improve productivity, and create a safer and more efficient work environment.

Quality Functional Deployment (QFD) is a process used in product development and design to ensure that customer requirements are met. It is a systematic approach that translates customer needs into specific design goals and targets. QFD is also known as a supercharged C&E Matrix or House of Quality because it involves creating a matrix that relates customer requirements to specific design features and engineering characteristics. This matrix helps prioritize design efforts and ensure that customer needs are addressed throughout the product development process.

The statement is true because there are indeed two types of statistics: descriptive statistics and inferential statistics. Descriptive statistics involve summarizing and describing data through measures such as shape, center, and variation. On the other hand, inferential statistics involve making inferences and drawing conclusions about a population based on a sample, often through hypothesis testing. Therefore, the statement accurately describes the two main branches of statistics.

The statement is true because common cause and special cause are indeed two types of variation in statistical process control. Common cause variation refers to the natural variation that is inherent in a process and is caused by factors that are consistently present. Special cause variation, on the other hand, is caused by factors that are not consistently present and can be attributed to specific events or circumstances. Understanding and distinguishing between these two types of variation is crucial in quality control and process improvement.

The two phases of the Design Phase are Conceptual and Detail. In the Conceptual phase, the overall design concept and ideas are developed, including brainstorming, sketching, and creating initial prototypes. This phase focuses on the big picture and defining the project's goals and objectives. In the Detail phase, the design concept is refined and finalized, including creating detailed drawings, specifications, and plans. This phase focuses on the specifics and ensuring that all aspects of the design are well-defined and ready for implementation.

The correct order of the Customer Life Cycle is as follows: Acquisition, Retention, Attrition, Defection, Re-acquisition. This order represents the typical stages that a customer goes through in their relationship with a company. First, the company acquires new customers. Then, they focus on retaining those customers and preventing attrition. However, some customers may still defect and stop doing business with the company. In response, the company may try to re-acquire those lost customers.

Identify – the opportunities and objectives
Define – the requirements
Design – the entity(product/service/process)
Optimize – the design
Validate – objectives met and sustainable

The correct answer is "Customer". The Customer Life Cycle refers to the stages that a customer goes through from the initial acquisition of a product or service, to their retention as a loyal customer, potential attrition or defection, and the possibility of reacquiring them. This cycle helps businesses understand and manage their customer relationships more effectively, ensuring they can attract and retain customers, as well as win back any lost customers.

Control charts are statistical tools used to monitor and analyze process variation. They identify the presence of special causes of variation, such as shifts or trends in the data, which can indicate problems or changes in the process. By monitoring the variation, control charts help to identify when a process is out of control and in need of corrective action. Therefore, the correct answer is "Variation."

In the Validate phase, full scale deployment and transfer ownership occur. This phase is the final step in the project management process, where the project is tested and evaluated to ensure that it meets all the requirements and objectives. Full scale deployment refers to the implementation of the project on a larger scale, while transfer ownership involves handing over the project to the appropriate stakeholders or users. Therefore, the Validate phase is the correct answer for this question.

A Design for Six Sigma (DFSS) Project can be created under all of the mentioned conditions. This means that a DFSS project can be initiated when there is no existing process, product, or service; when the current process, product, or service does not meet customer or company requirements; when there is no incremental improvement sufficient or possible to the existing process, product, or service; or when the proposed improvement is a new process, product, or service. In all these situations, implementing a DFSS project can help in designing and developing a new process, product, or service that meets the desired requirements and improves overall performance.

TRIZ stands for Theory of Inventive Problem Solving. TRIZ is a methodology developed by Genrich Altshuller, a Russian engineer, to solve complex problems and stimulate innovation. It provides a systematic approach to problem-solving by using a set of principles, patterns, and tools. TRIZ aims to identify inventive solutions by analyzing contradictions and finding ways to resolve them. It has been widely used in various industries to enhance product development, process improvement, and problem-solving capabilities.

Measures of variation are statistical tools used to describe the spread or dispersion of a data set. The median is not a measure of variation, but rather a measure of central tendency. It represents the middle value in a data set when it is arranged in ascending or descending order. In contrast, measures of variation such as standard deviation, variance, and range provide information about how spread out the data points are from the central value. Therefore, the median is not included in the measures of variation.

The KANO model is a theory that categorizes customer needs into three types: Basic, Desired, and Delighters. This model explains the relationship between performance and customer satisfaction. Over time, the classification of these needs can change, with Attractive characteristics becoming Desired and Desired characteristics becoming Basic. The KANO model helps businesses understand and prioritize customer needs to improve their products or services.

Developing the Project Plan is done in the Define phase. In this phase, the project objectives, scope, deliverables, and timeline are clearly defined. The project plan outlines the tasks, resources, and budget required for successful project completion. It also includes risk assessment and mitigation strategies. This phase sets the foundation for the project and ensures that all stakeholders have a clear understanding of the project's goals and how they will be achieved.

The range is not a measure of central tendency because it does not provide information about the central or typical value of a dataset. Instead, the range simply represents the difference between the maximum and minimum values in a dataset. Measures of central tendency, such as the mode, median, and mean, are used to describe the central or average value of a dataset.

Risk assessment is a crucial step in every phase of a project. In the identify phase, risks are identified and analyzed to understand potential threats and their impact. In the define phase, risks are further evaluated and prioritized to develop strategies for risk mitigation. In the design phase, risks are considered while designing the project to ensure that potential risks are minimized. In the optimize phase, risks are continuously monitored and evaluated to optimize risk management strategies. In the validate phase, risks are assessed to validate the effectiveness of risk mitigation measures. Therefore, risk assessment is a part of all the mentioned phases.

If there is an existing process that already meets customer and company requirements, it is most likely that process management would be required. This involves monitoring, controlling, and improving the existing process to ensure its continued effectiveness and efficiency. A DMAIC project (Define, Measure, Analyze, Improve, Control) or a DFSS project (Design for Six Sigma) may not be necessary in this case since the process is already meeting the requirements. Therefore, the correct answer is process management.

Design and development decisions have a significant impact on the overall Life Cycle Costs of a product. These decisions determine the materials, manufacturing processes, and technologies used, which in turn affect the cost of production, maintenance, and repairs throughout the product's life cycle. The range of 70-85% suggests that a large majority of the Life Cycle Costs are influenced by design and development decisions, indicating the importance of making informed choices during these stages to minimize costs and maximize efficiency.

The given answer of 80% suggests that a significant majority of quality problems are caused by poor design. This indicates that the design phase of a product or process plays a crucial role in determining its overall quality. It implies that if the design is flawed or inadequate, it is highly likely to result in quality issues. This answer highlights the importance of focusing on and improving the design aspect to minimize quality problems and enhance overall quality.

During the Define phase of a project, the business case is validated. This phase involves clearly defining the project objectives, scope, and requirements. It is during this phase that the project team verifies the feasibility and viability of the business case. They assess whether the project aligns with the organization's goals and if it is worth pursuing. This validation process helps ensure that resources are allocated appropriately and that the project will deliver the expected benefits.

The Champion cannot delegate this responsbility or the work.

In the context of the question, the term "pilot" refers to a trial or test run of a project or system. The phase in which a pilot occurs is the validation phase. This phase involves testing and verifying that the project or system meets the intended requirements and functions correctly before it is fully implemented. Therefore, the correct answer is "Validate."

A Morph Box is used to form multiple ideas into a concept or concepts. It allows for the evaluation and analysis of alternatives to find the best concept. By combining different ideas and elements, the Morph Box helps in generating innovative and creative solutions. It encourages thinking outside the box and promotes the exploration of different possibilities, leading to the development of new concepts.

In the DFSS (Design for Six Sigma) methodology, establishing parameters and tolerances occurs during the Optimize phase. This phase focuses on optimizing the design of the product or process by identifying the best combination of parameters and tolerances to meet customer requirements and minimize variation. It involves conducting experiments and simulations to determine the optimal design and validate its performance. This phase comes after the Define and Design phases, where the problem is identified and the initial design is developed.

The correct answer is 70%. The design phase of a project has a significant influence on the total life cycle cost. This is because decisions made during the design phase can impact the efficiency, functionality, and durability of the project, which in turn affects the cost of construction, operation, and maintenance. Therefore, it is crucial to carefully consider and optimize the design phase to minimize life cycle costs.

In the Design phase, the process of defining material, supply, and other input requirements takes place. This phase involves creating a detailed plan or blueprint for the project, including the specifications and requirements for the materials and inputs needed. It is during this phase that the project team determines the necessary resources and inputs to successfully carry out the project.

The model or prototype is done in the Optimize phase. This phase comes after the Identify, Define, and Design phases, where the problem is identified, defined, and a solution is designed. In the Optimize phase, the solution is refined and improved to achieve the best possible outcome. The Validate phase comes after the Optimize phase, where the solution is tested and validated for its effectiveness.

In the design phase, the process of simplifying the design takes place. This phase involves creating a detailed plan or blueprint for the project, considering all the requirements and constraints. Simplifying the design means finding ways to make it more efficient, cost-effective, and user-friendly. This may involve removing unnecessary elements, streamlining processes, or reducing complexity. Therefore, the correct answer is Design.