Comprehensive Six Sigma Principles, DMAIC, and Quality Management – 100+ MCQ with Answers
Q1. Who is considered the father of Six Sigma?
A. Edward Deming
B. Bill Smith
C. Michael Harry
D. Bob Galvin
✅ Answer: B. Bill Smith
Q2. The term “Six Sigma” was coined by:
A. Michael Harry
B. Bob Galvin
C. Bill Smith
D. Joseph Juran
✅ Answer: C. Bill Smith
Q3. The Six Sigma philosophy primarily focuses on:
A. Reducing variation and defects
B. Increasing cost efficiency
C. Enhancing brand visibility
D. Shortening production cycles
✅ Answer: A. Reducing variation and defects
Q4. Which of the following best describes Six Sigma?
A. Marketing framework
B. Data-driven methodology for process improvement
C. Financial audit system
D. Software development lifecycle
✅ Answer: B. Data-driven methodology for process improvement
Q5. Six Sigma aims to achieve:
A. 100% perfection
B. 3.4 defects per million opportunities
C. 0.34% defect rate
D. 99% accuracy
✅ Answer: B. 3.4 defects per million opportunities
Q6. The Six Sigma methodology primarily applies to:
A. Manufacturing only
B. Services only
C. Both goods and services
D. Design only
✅ Answer: C. Both goods and services
Q7. The main objective of Six Sigma is to:
A. Increase advertisement spend
B. Improve process performance by reducing variation
C. Replace traditional management
D. Eliminate all employees’ decision-making
✅ Answer: B. Improve process performance by reducing variation
Q8. Which statement reflects Six Sigma’s core philosophy?
A. Focus on profits over processes
B. Focus on process improvement and control
C. Focus on automation only
D. Focus on customer acquisition
✅ Answer: B. Focus on process improvement and control
Q9. The foundation of Six Sigma originated at which company?
A. General Electric
B. Motorola
C. IBM
D. Toyota
✅ Answer: B. Motorola
Q10. Who introduced the "belt" hierarchy concept in Six Sigma?
A. Bill Smith
B. Edward Deming
C. Michael Harry
D. Joseph Juran
✅ Answer: C. Michael Harry
Q11. In what year did Bob Galvin challenge Motorola to improve quality tenfold?
A. 1981
B. 1987
C. 1991
D. 1999
✅ Answer: A. 1981
Q12. Six Sigma was officially implemented at Motorola in:
A. 1985
B. 1987
C. 1989
D. 1990
✅ Answer: B. 1987
Q13. According to Edward Deming, quality is:
A. Conformance to specifications
B. Fitness for use
C. Anything that enhances customer satisfaction
D. A function of robust design
✅ Answer: C. Anything that enhances customer satisfaction
Q14. Joseph Juran defined quality as:
A. Conformance to specifications
B. Fitness for use
C. Absence of defects
D. Meeting cost targets
✅ Answer: B. Fitness for use
Q15. Philip Crosby’s definition of quality is:
A. Conformance to specifications
B. Meeting customer expectations
C. Reducing process variation
D. Continuous improvement
✅ Answer: A. Conformance to specifications
Q16. Genichi Taguchi emphasized quality through:
A. Robust design
B. Customer interviews
C. Process automation
D. Advertising
✅ Answer: A. Robust design
Q17. Taguchi’s “Design of Experiment” helps in:
A. Conducting multiple random tests
B. Finding the best parameter combination with minimal experiments
C. Reducing team conflicts
D. Improving branding strategies
✅ Answer: B. Finding the best parameter combination with minimal experiments
Q18. Variability that occurs naturally in a process is called:
A. Assignable cause
B. Natural variation
C. Controlled variation
D. Non-statistical error
✅ Answer: B. Natural variation
Q19. Variation caused by identifiable sources is termed:
A. Random variation
B. Special cause variation
C. Normal deviation
D. Common cause variation
✅ Answer: B. Special cause variation
Q20. A tolerance of 20mm ± 2mm is an example of:
A. Unilateral tolerance
B. Bilateral tolerance
C. Zero tolerance
D. Quality tolerance
✅ Answer: B. Bilateral tolerance
Q21. When variation is only checked on one side, it is:
A. Bilateral tolerance
B. Unilateral tolerance
C. Normal tolerance
D. Dual tolerance
✅ Answer: B. Unilateral tolerance
Q22. CTQ in Six Sigma stands for:
A. Critical To Quality
B. Cost To Quantity
C. Core Test Quotient
D. Control Time Quality
✅ Answer: A. Critical To Quality
Q23. The main focus of a Six Sigma project should be on:
A. Multiple outputs simultaneously
B. One Critical To Quality output
C. Departmental goals
D. Manager’s targets
✅ Answer: B. One Critical To Quality output
Q24. Which of the following is NOT a phase in DMAIC?
A. Define
B. Measure
C. Analyze
D. Develop
✅ Answer: D. Develop
Q25. The primary goal of the Define phase is to:
A. Collect data
B. Define the problem and project scope
C. Test solutions
D. Standardize control charts
✅ Answer: B. Define the problem and project scope
Q26. During the Measure phase, the main objective is to:
A. Implement solutions
B. Establish baseline performance
C. Control new processes
D. Train Green Belts
✅ Answer: B. Establish baseline performance
Q27. Which phase identifies root causes of the problem?
A. Define
B. Measure
C. Analyze
D. Control
✅ Answer: C. Analyze
Q28. The Improve phase focuses on:
A. Developing and implementing solutions
B. Reviewing financial impact
C. Hiring consultants
D. Collecting raw data
✅ Answer: A. Developing and implementing solutions
Q29. The Control phase ensures:
A. Process variation
B. Sustained improvements
C. New project initiation
D. Employee satisfaction
✅ Answer: B. Sustained improvements
Q30. Which of the following is specific to design projects in Six Sigma?
A. DMAIC
B. DMADV
C. SPC
D. QFD
✅ Answer: B. DMADV
Q31. The “D” in DMADV stands for:
A. Define and Design
B. Develop and Deliver
C. Decide and Document
D. Determine and Deploy
✅ Answer: A. Define and Design
Q32. The top-level authority in Six Sigma projects is the:
A. Green Belt
B. Master Black Belt
C. Champion
D. Process Owner
✅ Answer: C. Champion
Q33. Who acts as the full-time project leader in Six Sigma?
A. Master Black Belt
B. Black Belt
C. Green Belt
D. Yellow Belt
✅ Answer: B. Black Belt
Q34. A Green Belt typically works on projects:
A. Full-time
B. Part-time while performing their regular job
C. Only as supervisors
D. As auditors
✅ Answer: B. Part-time while performing their regular job
Q35. Which belt focuses mainly on basic awareness of Six Sigma concepts?
A. Yellow Belt
B. Green Belt
C. White Belt
D. Black Belt
✅ Answer: C. White Belt
Q36. The standard Six Sigma metric is measured in:
A. Percent defects
B. DPMO (Defects Per Million Opportunities)
C. Cp and Cpk indices
D. Sigma ratio
✅ Answer: B. DPMO
Q37. A Six Sigma level corresponds to approximately:
A. 34 DPMO
B. 3.4 DPMO
C. 0.34 DPMO
D. 340 DPMO
✅ Answer: B. 3.4 DPMO
Q38. Six Sigma’s problem-solving structure converts a business problem into:
A. A marketing strategy
B. A statistical problem
C. A financial model
D. A management decision
✅ Answer: B. A statistical problem
Q39. The Malgudi Hospital case is used to illustrate:
A. Cost-cutting techniques
B. Application of Six Sigma methodology
C. Product design optimization
D. Financial restructuring
✅ Answer: B. Application of Six Sigma methodology
Q40. The analogy of Six Sigma as a “detective” highlights its focus on:
A. Guesswork
B. Identifying and eliminating process causes
C. Delegation
D. Team training
✅ Answer: B. Identifying and eliminating process causes
Q41. Measurement system validation ensures:
A. Error minimization in data collection
B. Team participation
C. Budget control
D. Belt promotion
✅ Answer: A. Error minimization in data collection
Q42. The key tool used in the Define phase is:
A. Voice of Customer (VOC) analysis
B. Control chart
C. Histogram
D. Regression analysis
✅ Answer: A. Voice of Customer (VOC) analysis
Q43. Which phase involves hypothesis testing and root cause validation?
A. Define
B. Measure
C. Analyze
D. Improve
✅ Answer: C. Analyze
Q44. The Control phase uses tools such as:
A. SOPs and monitoring plans
B. Brainstorming and pilot testing
C. Pareto chart
D. Data sampling
✅ Answer: A. SOPs and monitoring plans
Q45. The organization that certifies Six Sigma professionals globally is:
A. ASQ
B. ISO
C. PMI
D. GE Institute
✅ Answer: A. ASQ
Q46. The acronym DPMO in Six Sigma stands for:
A. Defects Per Million Opportunities
B. Defects Per Measurement Output
C. Data Per Million Outputs
D. Deviations Per Method Outcome
✅ Answer: A. Defects Per Million Opportunities
Q47. The main statistical approach behind Six Sigma focuses on:
A. Eliminating all process costs
B. Reducing variation to improve quality
C. Enhancing product marketing
D. Expanding labor efficiency
✅ Answer: B. Reducing variation to improve quality
Q48. The sigma level of a process represents:
A. The time required for completion
B. The process’s deviation from perfection
C. The cost per product
D. The output per employee
✅ Answer: B. The process’s deviation from perfection
Q49. Which of the following represents a Six Sigma level process capability (Cp)?
A. 1.33
B. 1.67
C. 2.0
D. 3.4
✅ Answer: C. 2.0
Q50. A process performing at 99.73% yield corresponds to approximately:
A. 3 Sigma
B. 4 Sigma
C. 5 Sigma
D. 6 Sigma
✅ Answer: C. 5 Sigma
Q51. In Six Sigma, “Y = f(X)” represents:
A. The output (Y) is a function of multiple inputs (X)
B. The defect rate equals sigma
C. The cost equals input function
D. The variance equals time
✅ Answer: A. The output (Y) is a function of multiple inputs (X)
Q52. Which tool helps visualize variation in a process?
A. Pareto Chart
B. Control Chart
C. Ishikawa Diagram
D. Flowchart
✅ Answer: B. Control Chart
Q53. Which of the following is used in the Analyze phase to identify relationships between variables?
A. Scatter Plot
B. SIPOC Diagram
C. Brainstorming
D. SIPOC Chart
✅ Answer: A. Scatter Plot
Q54. SIPOC stands for:
A. Supplier, Input, Process, Output, Customer
B. System, Input, Performance, Outcome, Control
C. Strategy, Implementation, Performance, Output, Cost
D. Service, Information, Product, Output, Customer
✅ Answer: A. Supplier, Input, Process, Output, Customer
Q55. The “Voice of Customer” (VOC) is most relevant during which DMAIC phase?
A. Measure
B. Define
C. Control
D. Analyze
✅ Answer: B. Define
Q56. A histogram is most useful for:
A. Showing how data are distributed
B. Comparing two proportions
C. Tracking trends over time
D. Listing defects by frequency
✅ Answer: A. Showing how data are distributed
Q57. Pareto analysis is based on which principle?
A. 50/50 Rule
B. 80/20 Rule
C. 60/40 Rule
D. 70/30 Rule
✅ Answer: B. 80/20 Rule
Q58. Fishbone diagrams are also known as:
A. Tree diagrams
B. Cause and Effect diagrams
C. Affinity diagrams
D. Flowcharts
✅ Answer: B. Cause and Effect diagrams
Q59. The main purpose of a Cause-and-Effect diagram is to:
A. Identify root causes of a problem
B. Calculate standard deviation
C. Define customer requirements
D. Evaluate costs
✅ Answer: A. Identify root causes of a problem
Q60. In Six Sigma, a process map is used to:
A. Visualize how a process flows
B. Assign team members
C. Develop cost budgets
D. Create statistical models
✅ Answer: A. Visualize how a process flows
Q61. Which of the following is a measure of central tendency?
A. Mean
B. Range
C. Standard deviation
D. Variance
✅ Answer: A. Mean
Q62. The dispersion or spread of data is represented by:
A. Mode
B. Median
C. Standard deviation
D. Frequency
✅ Answer: C. Standard deviation
Q63. Process capability index (Cpk) measures:
A. Employee satisfaction
B. Customer retention
C. How well a process fits within specifications
D. Production volume
✅ Answer: C. How well a process fits within specifications
Q64. If Cpk < 1, it indicates:
A. Process is capable
B. Process is not meeting specifications
C. Process is stable
D. Process is optimized
✅ Answer: B. Process is not meeting specifications
Q65. Measurement system analysis (MSA) evaluates:
A. Data accuracy and reliability
B. Team performance
C. Financial impact
D. Supplier quality
✅ Answer: A. Data accuracy and reliability
Q66. Gage R&R stands for:
A. Gage Repeatability and Reproducibility
B. Gage Reliability and Retention
C. Group Accuracy and Response
D. Global Accuracy Rate
✅ Answer: A. Gage Repeatability and Reproducibility
Q67. Process variation that is random and unavoidable is called:
A. Special cause variation
B. Common cause variation
C. Assigned cause
D. Residual variation
✅ Answer: B. Common cause variation
Q68. Control charts are designed to monitor:
A. Trends and process stability
B. Employee morale
C. Revenue targets
D. Supplier contracts
✅ Answer: A. Trends and process stability
Q69. The “Center Line” in a control chart represents:
A. The target value or process mean
B. The upper tolerance limit
C. The cost of defects
D. The control limits
✅ Answer: A. The target value or process mean
Q70. When data points fall outside the control limits, it indicates:
A. Common cause variation
B. Random noise
C. Special cause variation
D. Operator error only
✅ Answer: C. Special cause variation
Q71. The “Improve” phase often uses which technique?
A. Brainstorming potential solutions
B. Root cause analysis
C. Measurement validation
D. Hypothesis testing
✅ Answer: A. Brainstorming potential solutions
Q72. A pilot implementation is conducted in which DMAIC phase?
A. Analyze
B. Improve
C. Measure
D. Define
✅ Answer: B. Improve
Q73. The “Control” phase ensures improvements are:
A. Permanent and measurable
B. Short-term and flexible
C. Optional
D. Costly
✅ Answer: A. Permanent and measurable
Q74. A Control Plan typically includes:
A. Monitoring methods and response strategies
B. Salary structures
C. Training feedback
D. Project finance
✅ Answer: A. Monitoring methods and response strategies
Q75. Poka-Yoke refers to:
A. Error-proofing techniques
B. Team collaboration
C. Process mapping
D. Data analysis
✅ Answer: A. Error-proofing techniques
Q76. “Design for Six Sigma” (DFSS) emphasizes:
A. Redesigning an existing process
B. Creating new processes or products right the first time
C. Marketing analytics
D. Inventory control
✅ Answer: B. Creating new processes or products right the first time
Q77. The first step in DFSS (DMADV) is:
A. Define
B. Measure
C. Design
D. Verify
✅ Answer: A. Define
Q78. Verification in DMADV ensures:
A. Customer satisfaction and design performance
B. Market share growth
C. Low employee turnover
D. Supplier compliance
✅ Answer: A. Customer satisfaction and design performance
Q79. Six Sigma focuses primarily on which type of performance metric?
A. Financial metrics
B. Process metrics
C. HR metrics
D. Brand awareness
✅ Answer: B. Process metrics
Q80. Cost of Poor Quality (COPQ) includes:
A. Rework, scrap, warranty, and lost goodwill
B. Marketing expenditure
C. Fixed costs only
D. Employee training
✅ Answer: A. Rework, scrap, warranty, and lost goodwill
Q81. “Voice of Business” (VOB) is mainly concerned with:
A. Internal efficiency and profitability
B. Customer emotions
C. Employee feedback
D. Product design
✅ Answer: A. Internal efficiency and profitability
Q82. Which chart is best for showing the frequency of defects by category?
A. Pareto chart
B. Histogram
C. Control chart
D. Pie chart
✅ Answer: A. Pareto chart
Q83. Which tool is used to prioritize problem areas in a project?
A. Pareto analysis
B. Brainstorming
C. Scatter diagram
D. Process mapping
✅ Answer: A. Pareto analysis
Q84. Which Six Sigma role leads multiple projects and mentors Black Belts?
A. Master Black Belt
B. Green Belt
C. Champion
D. Process Owner
✅ Answer: A. Master Black Belt
Q85. Champions in Six Sigma are typically:
A. Senior executives
B. Junior employees
C. Data analysts
D. Consultants
✅ Answer: A. Senior executives
Q86. The concept “Process over People” implies:
A. Blaming processes, not employees, for defects
B. Ignoring human error
C. Firing employees
D. Automating everything
✅ Answer: A. Blaming processes, not employees, for defects
Q87. Which of these statements best defines Lean Six Sigma?
A. A combination of waste elimination and defect reduction techniques
B. A replacement for Six Sigma
C. A marketing strategy
D. A motivational framework
✅ Answer: A. A combination of waste elimination and defect reduction techniques
Q88. The Control phase uses which tool to maintain improvements?
A. Control chart
B. Histogram
C. Check sheet
D. Flowchart
✅ Answer: A. Control chart
Q89. The Voice of Process (VOP) refers to:
A. Internal performance data of a process
B. Customer surveys
C. Management goals
D. Supplier reviews
✅ Answer: A. Internal performance data of a process
Q90. Six Sigma projects must align with:
A. Organizational strategy and customer needs
B. HR policies
C. Budget cycles
D. Supplier schedules
✅ Answer: A. Organizational strategy and customer needs
Q91. The measure of process performance over time is known as:
A. Process capability
B. Process stability
C. Process yield
D. Process bias
✅ Answer: B. Process stability
Q92. A process operating at 4 Sigma typically has how many defects per million opportunities?
A. 6210
B. 233
C. 63
D. 3.4
✅ Answer: A. 6210
Q93. The key deliverable of the Define phase is:
A. Project charter
B. Control plan
C. Measurement system analysis
D. Pilot study
✅ Answer: A. Project charter
Q94. The “Measure” phase ensures data collection is:
A. Valid, consistent, and repeatable
B. Random and unverified
C. Based on assumptions
D. Optional
✅ Answer: A. Valid, consistent, and repeatable
Q95. Statistical thinking in Six Sigma involves:
A. Understanding that all work occurs in processes with variation
B. Assuming perfection
C. Ignoring outliers
D. Using gut feelings
✅ Answer: A. Understanding that all work occurs in processes with variation
Q96. A key characteristic of Six Sigma culture is:
A. Data-driven decision making
B. Top-down management only
C. Employee guesswork
D. Product marketing
✅ Answer: A. Data-driven decision making
Q97. The overall philosophy of Six Sigma is based on:
A. Continuous improvement
B. One-time optimization
C. Temporary fixes
D. Employee rewards
✅ Answer: A. Continuous improvement
Q98. Benchmarking in Six Sigma helps:
A. Compare process performance with best practices
B. Increase salaries
C. Reduce competition
D. Hire more staff
✅ Answer: A. Compare process performance with best practices
Q99. Which statistical test is commonly used to validate differences between means?
A. ANOVA or t-test
B. Pareto
C. Control chart
D. Box plot
✅ Answer: A. ANOVA or t-test
Q100. In Six Sigma, “defect” is defined as:
A. Any deviation from customer requirements
B. A random event
C. A financial loss
D. An operator mistake only
✅ Answer: A. Any deviation from customer requirements
Q101. Which phase would include training the workforce on new standard procedures?
A. Control
B. Improve
C. Measure
D. Analyze
✅ Answer: A. Control
Q102. A “rolled throughput yield” (RTY) measures:
A. Probability of producing defect-free units across multiple steps
B. Supplier compliance rate
C. Cost of inputs
D. Employee efficiency
✅ Answer: A. Probability of producing defect-free units across multiple steps
Q103. The most data-intensive phase of DMAIC is:
A. Measure
B. Define
C. Control
D. Improve
✅ Answer: A. Measure
Q104. The statistical term “Sigma” refers to:
A. Standard deviation
B. Average value
C. Process mean
D. Range
✅ Answer: A. Standard deviation
Q105. Which of the following is a proactive Six Sigma activity?
A. DMADV
B. DMAIC
C. 5 Whys
D. SIPOC
✅ Answer: A. DMADV
Q106. The “5 Whys” technique is used for:
A. Root cause analysis
B. Hypothesis testing
C. Control validation
D. Data measurement
✅ Answer: A. Root cause analysis
Q107. The key performance indicator in Six Sigma is:
A. Defect rate
B. Profit margin
C. Market share
D. Employee satisfaction
✅ Answer: A. Defect rate
Q108. The statistical foundation of Six Sigma was derived from:
A. Normal distribution
B. Poisson distribution
C. Binomial distribution
D. Exponential distribution
✅ Answer: A. Normal distribution
Q109. The ultimate goal of Six Sigma is to:
A. Achieve near-perfect quality through data and process control
B. Increase employee count
C. Reduce expenses only
D. Maximize brand visibility
✅ Answer: A. Achieve near-perfect quality through data and process control
Q110. In summary, Six Sigma combines:
A. Statistical discipline + Management philosophy
B. Marketing + Sales
C. Finance + HR
D. Design + Advertising
✅ Answer: A. Statistical discipline + Management philosophy
Six Sigma questions and answers, DMAIC methodology quiz, Six Sigma belts hierarchy, quality improvement MCQs, process variation, DPMO, Lean Six Sigma, Six Sigma certification preparation, data-driven decision making, continuous improvement quiz
