Free ICGB sample questions

Correct answer: RPN = 168; serves as a relative priority for focusing improvement efforts.

The Risk Priority Number (RPN) is calculated by multiplying the scores for Severity, Occurrence, and Detection (S x O x D). In this case, RPN = 8 x 3 x 7 = 168. The RPN is not an absolute measure but a relative one, used to rank and prioritize potential failure modes. Teams use the RPN to focus their limited resources on mitigating the highest-risk items first.

Correct answers: Perform root cause analysis to understand the sources of variation.; Use tools like Fishbone diagrams and the 5 Whys.

A Cpk of 0.75 indicates the process is not capable of meeting specifications. Since the process is stable, the issue is common cause variation, not special cause events. The next logical step in DMAIC is to move to the Analyze phase to find the root causes of this inherent variation.

Fishbone diagrams and the 5 Whys are primary tools used in the Analyze phase for root cause analysis. They help the team systematically explore and identify the underlying factors (the 'vital few' x's) that are contributing to the process variation and causing the low capability.

Correct answer: True

This statement is true. The core principle of a 'pull' system, a fundamental concept in Lean, is to link production directly to customer or downstream process demand. This prevents the waste of overproduction, which is often considered the worst form of waste because it generates other wastes like excess inventory, transportation, and waiting.

Correct answer: 85% of the variation in the number of defects can be explained by the variation in the number of lines of code.

R-squared, also known as the coefficient of determination, measures the proportion of the variance in the dependent variable (Y) that is predictable from the independent variable(s) (X). An R-sq of 85% means that 85% of the observed variation in the number of defects is explained by the linear relationship with the number of lines of code. It does not imply causation.

Correct answer: Develop clear operational definitions for each timestamp and conduct a Measurement System Analysis (MSA) to quantify the measurement error.

The principle of 'garbage in, garbage out' is critical in Six Sigma. Before any process analysis can be trusted, the measurement system itself must be validated. The lack of synchronized systems and manual entry points to significant potential measurement error. The most critical step is to establish clear operational definitions for exactly what 'Order-to-Delivery Time' and its components mean, and then perform an MSA (like a Gage R&R study, modified for a transactional process) to understand and quantify the error in the data. Without this, any conclusions drawn in the Analyze phase would be invalid.

Correct answer: Pareto Chart

A Pareto Chart is a bar chart where the bars are ordered from highest frequency to lowest, illustrating the 80/20 rule (Pareto Principle). This principle states that for many events, roughly 80% of the effects come from 20% of the causes. The chart visually separates the 'vital few' causes that contribute most to the problem from the 'trivial many', allowing teams to focus their efforts effectively.

Correct answer: Internal Failure Costs

Internal Failure Costs are incurred when defects are discovered before the product or service is delivered to the customer. Examples include the cost of rework, scrapping defective products, downgrading products, and machine downtime caused by defects. These are costs of nonconformance found within the organization.

Correct answer: Control Method (Prevention)

This is a Control Method, specifically a prevention-type Poka-Yoke. It physically prevents the error from occurring. Warning methods would only signal that an error has been made (e.g., a light or buzzer), but would not stop it from happening. The asymmetric pin design makes it impossible to assemble the part incorrectly, thus preventing the defect at the source.

Correct answer: Mann-Whitney Test

Ordinal data, like a 1-5 satisfaction scale, is non-parametric. A 2-sample t-test and ANOVA are parametric tests that assume continuous data and normality. The Mann-Whitney test is the appropriate non-parametric alternative to the 2-sample t-test for comparing two independent groups when the data is ordinal or not normally distributed. It compares the medians of the two groups.

Correct answers: It is not measurable.; It is too broad and lacks focus.

A strong problem statement must be measurable. 'Too low' is subjective and does not quantify the current level of performance or the gap between the current state and the desired state. It should include data, for example: 'The average customer satisfaction score has dropped from 4.5 to 3.2 over the last six months.'

'Customer satisfaction' is a very broad concept. A good problem statement should be specific. Is the dissatisfaction related to product quality, delivery time, customer service, or something else? A focused problem statement like 'Complaints regarding late deliveries have increased by 50% in Q3' is much more effective.