1. Reduce cycle time but quality drops. Which metric failed?

2. If DPMO is 3.4, the process sigma level is approximately

3. Reducing defect rate from 8% to 3% is

4. A project reduces defect rate by 1% but saves ₹5Cr annually. It should be prioritized based on

5. Which cost reduces after Six Sigma implementation?

6. A process produces 25 defects in 5,000 units. Each unit has 4 opportunities. What is DPMO?

7. Reducing lead time improves customer satisfaction but reduces profit margin. Conflict is between

8. A project reduces changeover time but increases scrap rate slightly. Which metric failed to be monitored properly?

9. A problem statement must include which combination?

10. Goal statement must include baseline and

11. Goal: “Improve quality significantly.” This lacks

12. Financial benefit must be validated by

13. Cycle time = 65 sec while takt time = 50 sec. This indicates

14. Inventory between processes primarily increases

15. If Customer Demand = 2400 units/month and available time is 25 working days running 3 shifts each of 8 hours. There are 30 minutes break in each shift. Takt time is

16. In 10,000 cables, 120 defects are found. Each cable has 4 CTQs. What is DPMO?

17. 100 defects in 10,000 units, 10 opp each. DPMO?

18. Observed Variation = Process Variation + _________________

19. If long-term sigma = 4.5, short-term sigma approx

20. Sample size = 5 per subgroup, continuous data. Chart?

21. In normal distribution, area under curve equals

22. Step yields: 0.98, 0.96, 0.95, 0.97. RTY ≈

23. Range is sensitive to

24. For skewed life data, preferred distribution is

25. Warranty reduction ₹40L/year classified as

26. Mean = 30, SD = 5. What % of area will be below 40?

27. Time between cable failures best modeled by

28. %GRR = 8%, NDC = 6. Measurement system is

29. If mean = 50, SD = 10, Z for value 70 is

30. Process A: μ=50, σ=5. Process B: μ=100, σ=8. Higher relative variation?

31. Points alternating high-low-high-low suggests

32. 7 points trending upward indicates

33. In Visial Management, Visual boards improve

34. Specification limits are based on

35. Dashboards mainly support

36. No defined reaction plan increases

37. When sample size varies and counting defects per unit

38. 9 consecutive points on one side CL indicates

39. Counting number of defects per unit (constant sample size)

40. Monitoring defectives proportion requires

41. Scatter Plot used to study

42. Project saves ₹80L/year, 3-year horizon, investment ₹1Cr. Net gain over 3 yrs =

43. In Regression Analysis, VIF high indicates

44. Regression equation predicts

45. Higher RPN indicates

46. High correlation does not imply

47. In Regression Analysis, if p-value of slope >0.05, conclusion

48. When practical significance high but statistical not significant, next step

49. Severity = 8, Occurrence = 5, Detection = 4. RPN equals

50. If top 3 causes contribute 75% defects, strategy should

51. Cp=1.8, Cpk=1.7, process unstable. First action?

52. Machine A produces 100 units and 12 are failed, Machine B produces 200 units and 10 are failed. If you perform hypothesis test, what will be the decision?

53. Cp high but Cpk low indicates

54. Process in control, Cp=1.2, Cpk=1.2. Customer complaints continue. Most likely cause

55. Mean=200, SD=20. Spec=240. Z =

56. If detection improved but occurrence high, long-term risk remains due to

57. Reducing variation supports Lean by

58. Inventory reduced by ₹2Cr, carrying cost 12%. Annual saving?

59. In DOE, Main effect measures

60. Large WIP triangles in VSM indicate

61. In Full Factorial DOE, 2 factors at 2 levels requires

62. In SMED, Converting internal to external setup reduces

63. Main advantage of Fractional Factorial DOE

64. In DOE 2⁴ Full Factorial, Number of runs required

65. Kaizen focuses on

66. If Detection improves from 8 to 3 (S=7, O=5), new RPN =

67. Best factor combination in DOE selected based on

68. In Fractional Factorial DOE, 2⁴⁻¹ design requires

69. Response increases with higher temp but decreases after threshold. This suggests

70. Takt mismatch across stations causes

71. Perfection principle in Lean means

72. Jumping to Improve before validating X’s causes

73. Skipping Measure and directly analyzing leads to

74. Lean reduces waste, Six Sigma reduces

75. Lean without Six Sigma may improve speed but risk