Six Sigma | DMAIC, CTQ, COPQ, Metrics & Roles | 100+ MCQ with Answers
Q1. Six Sigma is primarily a _______.
A. Marketing strategy
B. Data-driven management methodology
C. Financial audit tool
D. Human resource initiative
✅ Answer: B. Data-driven management methodology
Q2. The core aim of Six Sigma is to reduce _______.
A. Product design time
B. Process variation and defects
C. Employee turnover
D. Marketing costs
✅ Answer: B. Process variation and defects
Q3. Six Sigma converts a business problem into _______.
A. A leadership challenge
B. A statistical problem and back into a business solution
C. A quality assurance checklist
D. A project charter
✅ Answer: B. A statistical problem and back into a business solution
Q4. Six Sigma decisions are primarily based on _______.
A. Personal judgment
B. Market trends
C. Data and evidence
D. Intuition and experience
✅ Answer: C. Data and evidence
Q5. Quality, as defined in Six Sigma, refers to _______.
A. The lowest cost
B. Fitness for purpose
C. Fastest delivery
D. Customer loyalty
✅ Answer: B. Fitness for purpose
Q6. Variation in Six Sigma processes is _______.
A. Avoided completely
B. Inevitable but controlled using tolerances
C. Not measurable
D. Ignored unless severe
✅ Answer: B. Inevitable but controlled using tolerances
Q7. “Critical to Quality” (CTQ) refers to _______.
A. Customer demographics
B. Measurable elements critical to performance
C. Cost accounting ratios
D. Supplier ratings
✅ Answer: B. Measurable elements critical to performance
Q8. CTQs originate from which of the following sources?
A. Voice of Customer and Voice of Business
B. Internal audit
C. Employee surveys
D. Supplier performance reports
✅ Answer: A. Voice of Customer and Voice of Business
Q9. “Voice of Customer” (VOC) mainly focuses on _______.
A. Financial savings
B. Process efficiency
C. Process effectiveness and satisfaction
D. Operational cost reduction
✅ Answer: C. Process effectiveness and satisfaction
Q10. “Voice of Business” (VOB) represents _______.
A. Internal profitability or cost efficiency
B. Employee concerns
C. Government regulations
D. Supplier performance
✅ Answer: A. Internal profitability or cost efficiency
Q11. The sequential methodology followed in Six Sigma projects is known as _______.
A. PDCA
B. DMAIC
C. PERT
D. DMADV
✅ Answer: B. DMAIC
Q12. The purpose of the Define phase in Six Sigma is to _______.
A. Generate the project idea and define the problem (Y)
B. Implement the control plan
C. Train employees
D. Measure process speed
✅ Answer: A. Generate the project idea and define the problem (Y)
Q13. Which of the following is not a step in the Define phase?
A. Project identification
B. Project charter development
C. Process mapping
D. Root cause analysis
✅ Answer: D. Root cause analysis
Q14. The document that formally authorizes a Six Sigma project is the _______.
A. Project Charter
B. Process map
C. Control chart
D. Histogram
✅ Answer: A. Project Charter
Q15. A Project Charter typically includes all the following except:
A. Business case
B. Problem statement
C. Team picnic budget
D. Goal statement
✅ Answer: C. Team picnic budget
Q16. The “Business Case” in a Six Sigma project explains _______.
A. Why the project is important to the organization
B. The control phase details
C. The company’s mission
D. Employee performance reviews
✅ Answer: A. Why the project is important to the organization
Q17. Which of the following tools is used to convert broad customer needs into measurable requirements?
A. CTQ Tree
B. Pareto Chart
C. Gantt Chart
D. Scatter Diagram
✅ Answer: A. CTQ Tree
Q18. A CTQ Tree helps convert _______.
A. Customer complaints into measurable performance metrics
B. Process maps into business cases
C. Supplier ratings into control charts
D. Cost data into P-charts
✅ Answer: A. Customer complaints into measurable performance metrics
Q19. The CTQ “Wait time < 30 seconds” is derived from which customer statement?
A. “I don’t want to wait too long.”
B. “Prices are high.”
C. “The service is great.”
D. “I need more options.”
✅ Answer: A. “I don’t want to wait too long.”
Q20. An Affinity Diagram is used to _______.
A. Sort unstructured data into logical groups
B. Measure process defects
C. Create financial forecasts
D. Evaluate suppliers
✅ Answer: A. Sort unstructured data into logical groups
Q21. The Cost of Poor Quality (COPQ) quantifies _______.
A. Employee training costs
B. Losses due to inefficiency or defects
C. Marketing spend
D. Tax expenses
✅ Answer: B. Losses due to inefficiency or defects
Q22. COPQ is part of the broader concept known as _______.
A. Cost of Capital
B. Cost of Quality (COQ)
C. Process Benchmarking
D. Balanced Scorecard
✅ Answer: B. Cost of Quality (COQ)
Q23. According to Juran, the “Cost of Good Quality” includes which of the following?
A. Prevention and Appraisal Costs
B. Internal and External Failure Costs
C. Downtime and Warranty
D. Lost Sales
✅ Answer: A. Prevention and Appraisal Costs
Q24. Which of the following is an example of Internal Failure Cost?
A. Customer warranty claim
B. Scrap or rework before product reaches customer
C. Loss of customer
D. Product recall
✅ Answer: B. Scrap or rework before product reaches customer
Q25. Spending ₹10 on prevention can save approximately how much in failure cost according to Six Sigma logic?
A. ₹10
B. ₹20
C. ₹100
D. ₹1000
✅ Answer: C. ₹100
Q26. A high-level process overview tool used in the Define phase is called _______.
A. SIPOC
B. SWOT
C. PESTEL
D. RACI
✅ Answer: A. SIPOC
Q27. SIPOC stands for _______.
A. Supplier, Input, Process, Output, Customer
B. Strategy, Implementation, Performance, Output, Cost
C. System, Input, Product, Output, Control
D. Scope, Integration, Performance, Operations, Customer
✅ Answer: A. Supplier, Input, Process, Output, Customer
Q28. The main purpose of SIPOC is to _______.
A. Visualize process flow and boundaries
B. Train new employees
C. Analyze data variability
D. Track customer complaints
✅ Answer: A. Visualize process flow and boundaries
Q29. Tollgate Reviews are conducted to _______.
A. Approve budget for marketing
B. Ensure phase deliverables are met before next step
C. Replace process owners
D. Evaluate customer feedback
✅ Answer: B. Ensure phase deliverables are met before next step
Q30. The phase that identifies critical input variables (X) affecting outcomes (Y) is _______.
A. Define
B. Measure
C. Analyze
D. Control
✅ Answer: C. Analyze
Q31. Which Six Sigma phase primarily focuses on sustaining process gains?
A. Improve
B. Define
C. Control
D. Measure
✅ Answer: C. Control
Q32. Who among the following defines the project and provides resources in Six Sigma?
A. Champion or Sponsor
B. Green Belt
C. Yellow Belt
D. Process Operator
✅ Answer: A. Champion or Sponsor
Q33. Which role leads Six Sigma projects full-time?
A. Master Black Belt
B. Black Belt
C. Champion
D. Green Belt
✅ Answer: B. Black Belt
Q34. The Master Black Belt is responsible for _______.
A. Project funding
B. Strategic direction and mentoring Black Belts
C. Product design
D. Conducting Tollgate reviews only
✅ Answer: B. Strategic direction and mentoring Black Belts
Q35. Green Belts typically work on Six Sigma projects _______.
A. Full-time
B. Part-time along with their main job
C. As external consultants
D. Only during audits
✅ Answer: B. Part-time along with their main job
Q36. Yellow and White Belts contribute by _______.
A. Designing process maps
B. Providing process knowledge and assisting with data collection
C. Approving budgets
D. Leading strategic projects
✅ Answer: B. Providing process knowledge and assisting with data collection
Q37. Six Sigma levels are measured in terms of _______.
A. Revenue growth
B. Defects per million opportunities (DPMO)
C. Employee retention rate
D. Cycle time
✅ Answer: B. Defects per million opportunities (DPMO)
Q38. The benchmark defect rate at Six Sigma performance level is _______.
A. 34%
B. 3.4 defects per million opportunities
C. 340 defects per million opportunities
D. 0.34 defects per million opportunities
✅ Answer: B. 3.4 defects per million opportunities
Q39. Six Sigma as a philosophy emphasizes _______.
A. Guesswork and creative problem-solving
B. Data, discipline, and defect reduction
C. Employee motivation programs
D. Customer segmentation
✅ Answer: B. Data, discipline, and defect reduction
Q40. In Six Sigma, “Y” represents _______.
A. The process outcome or dependent variable
B. The process input
C. Random variation
D. Control limits
✅ Answer: A. The process outcome or dependent variable
Q41. The ultimate goal of Six Sigma is to achieve _______.
A. Zero defects
B. Acceptable variation within tolerance
C. Complete automation
D. 100% customer satisfaction without data
✅ Answer: B. Acceptable variation within tolerance
Q42. Which of the following best describes DMAIC sequence?
A. Define → Measure → Analyze → Improve → Control
B. Design → Measure → Act → Implement → Check
C. Define → Manage → Apply → Integrate → Control
D. Determine → Model → Apply → Inspect → Close
✅ Answer: A. Define → Measure → Analyze → Improve → Control
Q43. A SMART goal in Six Sigma should be _______.
A. Simple, Marketable, Actionable, Realistic, Testable
B. Specific, Measurable, Achievable, Relevant, Time-bound
C. Sustainable, Meaningful, Accountable, Robust, Traceable
D. Speedy, Measurable, Accurate, Reliable, Transparent
✅ Answer: B. Specific, Measurable, Achievable, Relevant, Time-bound
Q44. Which phase verifies the improvements statistically?
A. Analyze
B. Measure
C. Improve
D. Control
✅ Answer: C. Improve
Q45. The project timeline section of a charter includes _______.
A. Key milestones for each DMAIC phase
B. Employee bonuses
C. Revenue projections
D. Supplier contracts
✅ Answer: A. Key milestones for each DMAIC phase
Q46. The primary focus of the Control phase is _______.
A. Analyzing variation
B. Sustaining and standardizing improvements
C. Setting financial goals
D. Collecting customer feedback
✅ Answer: B. Sustaining and standardizing improvements
Q47. A process map in Six Sigma helps to _______.
A. Visualize and understand process flow
B. Predict customer satisfaction
C. Track sales performance
D. Identify human resource gaps
✅ Answer: A. Visualize and understand process flow
Q48. In Six Sigma, efficiency is related to _______.
A. Voice of Customer
B. Voice of Business
C. Process mapping
D. VOC Tree
✅ Answer: B. Voice of Business
Q49. The Define phase deliverables include _______.
A. Approved Project Charter and Process Map
B. Control Plan and Process Capability
C. Regression Model
D. Improvement Plan
✅ Answer: A. Approved Project Charter and Process Map
Q50. Variation management in Six Sigma primarily aims to ensure _______.
A. Predictable and consistent performance
B. Increased profits only
C. Reduced staffing
D. Quick fixes
✅ Answer: A. Predictable and consistent performance
Q51. The primary goal of the Measure phase in Six Sigma is to _______.
A. Validate the problem and collect data
B. Develop marketing strategy
C. Create the process charter
D. Approve final solution
✅ Answer: A. Validate the problem and collect data
Q52. Data collection in Six Sigma should be based on _______.
A. Intuition
B. Facts and operational definitions
C. Random assumptions
D. Managerial feedback only
✅ Answer: B. Facts and operational definitions
Q53. Which metric represents the number of opportunities for a defect in Six Sigma?
A. DPU (Defects per Unit)
B. DPMO (Defects per Million Opportunities)
C. COPQ (Cost of Poor Quality)
D. DPO (Defects per Opportunity)
✅ Answer: B. DPMO (Defects per Million Opportunities)
Q54. The Measure phase output typically includes _______.
A. Process baseline and capability data
B. Control charts and SOPs
C. Supplier audit reports
D. Financial statements
✅ Answer: A. Process baseline and capability data
Q55. Measurement System Analysis (MSA) ensures that _______.
A. The measurement process is accurate and repeatable
B. Customers are satisfied
C. Costs are minimized
D. Defects are removed
✅ Answer: A. The measurement process is accurate and repeatable
Q56. The Analyze phase focuses on _______.
A. Identifying root causes of variation
B. Hiring new team members
C. Creating new process documentation
D. Measuring customer satisfaction only
✅ Answer: A. Identifying root causes of variation
Q57. Which tool is most commonly used in the Analyze phase for root cause analysis?
A. Fishbone Diagram (Cause-and-Effect)
B. Pareto Chart
C. Histogram
D. Control Chart
✅ Answer: A. Fishbone Diagram (Cause-and-Effect)
Q58. Pareto Analysis is based on which principle?
A. 80/20 Rule
B. 50/50 Principle
C. Law of Diminishing Returns
D. Juran’s Quality Spiral
✅ Answer: A. 80/20 Rule
Q59. The Improve phase focuses on _______.
A. Implementing and testing solutions
B. Gathering new data only
C. Writing final reports
D. Performing statistical audits
✅ Answer: A. Implementing and testing solutions
Q60. Which tool is commonly used to test improvement ideas?
A. Design of Experiments (DOE)
B. Fishbone Diagram
C. SIPOC
D. Gantt Chart
✅ Answer: A. Design of Experiments (DOE)
Q61. In the Control phase, control charts help _______.
A. Monitor process stability
B. Identify new customer needs
C. Create training modules
D. Build team morale
✅ Answer: A. Monitor process stability
Q62. Which of the following is a preventive control method?
A. Mistake proofing (Poka-Yoke)
B. Post-process inspection
C. Customer complaints
D. Supplier negotiations
✅ Answer: A. Mistake proofing (Poka-Yoke)
Q63. Process capability (Cp/Cpk) measures _______.
A. Process ability to meet specifications
B. Customer satisfaction
C. Marketing effectiveness
D. Employee productivity
✅ Answer: A. Process ability to meet specifications
Q64. Which of the following metrics is most directly related to Six Sigma performance?
A. Process capability index (Cpk)
B. Market share
C. Customer lifetime value
D. Employee engagement index
✅ Answer: A. Process capability index (Cpk)
Q65. A process performing at 6σ level produces _______.
A. 3.4 defects per million opportunities
B. 34 defects per thousand opportunities
C. 6 defects per hundred opportunities
D. 0 defects always
✅ Answer: A. 3.4 defects per million opportunities
Q66. The mathematical relationship in Six Sigma can be represented as _______.
A. Y = f(X)
B. X = f(Y)
C. Z = f(Q)
D. Y = X + Z
✅ Answer: A. Y = f(X)
Q67. “Y = f(X)” implies that _______.
A. The outcome (Y) depends on multiple inputs (X)
B. Inputs depend on output
C. Variation is random
D. Defects are unmeasurable
✅ Answer: A. The outcome (Y) depends on multiple inputs (X)
Q68. In Six Sigma, a stable process means _______.
A. Predictable performance with random variation only
B. High production speed
C. No customer complaints
D. Maximum profit margins
✅ Answer: A. Predictable performance with random variation only
Q69. Process variation that can be traced to a specific cause is called _______.
A. Special cause variation
B. Common cause variation
C. Random noise
D. Tolerance shift
✅ Answer: A. Special cause variation
Q70. A Control Chart helps differentiate between _______.
A. Special cause and common cause variation
B. Customer feedback and process input
C. Costs and savings
D. Quality and productivity
✅ Answer: A. Special cause and common cause variation
Q71. DMAIC is primarily used for _______.
A. Improving existing processes
B. Designing new processes
C. Benchmarking performance
D. Conducting HR audits
✅ Answer: A. Improving existing processes
Q72. DMADV is mainly applied in _______.
A. New process or product design
B. Ongoing quality control
C. Financial risk management
D. Customer service escalation
✅ Answer: A. New process or product design
Q73. The role of the Champion includes _______.
A. Project approval and resource allocation
B. Statistical analysis
C. Process mapping
D. Control chart interpretation
✅ Answer: A. Project approval and resource allocation
Q74. Green Belts are expected to _______.
A. Execute improvement projects within their function
B. Provide only administrative support
C. Manage company finances
D. Approve organization-wide policies
✅ Answer: A. Execute improvement projects within their function
Q75. The Belt responsible for mentoring and training is the _______.
A. Master Black Belt
B. Yellow Belt
C. Process Owner
D. Project Sponsor
✅ Answer: A. Master Black Belt
Q76. White Belts primarily contribute by _______.
A. Providing basic process understanding and assisting in data collection
B. Running statistical analyses
C. Approving project charters
D. Leading cross-functional teams
✅ Answer: A. Providing basic process understanding and assisting in data collection
Q77. Which of the following is a key benefit of Six Sigma implementation?
A. Reduced variation and improved customer satisfaction
B. Increased bureaucracy
C. Higher marketing spend
D. Reduced training time
✅ Answer: A. Reduced variation and improved customer satisfaction
Q78. A Six Sigma project delivering ₹500,000 annual savings relates to which section of the charter?
A. Business Case
B. Scope Statement
C. Team Composition
D. Tollgate Review
✅ Answer: A. Business Case
Q79. The SMART goal criterion ensures _______.
A. Clear, measurable and time-bound objectives
B. Continuous customer complaints
C. Ambiguous deliverables
D. Random project duration
✅ Answer: A. Clear, measurable and time-bound objectives
Q80. The primary reason for measuring Cost of Poor Quality (COPQ) is to _______.
A. Quantify the impact of process inefficiency
B. Determine competitor pricing
C. Increase taxes
D. Reduce employee salaries
✅ Answer: A. Quantify the impact of process inefficiency
Q81. The term “sigma” in Six Sigma denotes _______.
A. Standard deviation or variability
B. Average performance
C. Customer base size
D. Time of delivery
✅ Answer: A. Standard deviation or variability
Q82. The higher the sigma level, the _______.
A. Lower the defect rate
B. Higher the defect rate
C. Greater the cost
D. More variation in process
✅ Answer: A. Lower the defect rate
Q83. A process running at 4 sigma produces roughly _______.
A. 6,210 defects per million
B. 3.4 defects per million
C. 0 defects
D. 10,000 defects per million
✅ Answer: A. 6,210 defects per million
Q84. Six Sigma projects are generally aligned with _______.
A. Organizational strategic objectives
B. Competitor benchmarking only
C. Government regulations
D. HR performance appraisals
✅ Answer: A. Organizational strategic objectives
Q85. The equation “COPQ = Internal + External Failure Costs” excludes _______.
A. Prevention costs
B. Scrap and warranty
C. Rework
D. Downtime
✅ Answer: A. Prevention costs
Q86. The Affinity Diagram is most useful during which phase?
A. Define
B. Control
C. Improve
D. Analyze
✅ Answer: A. Define
Q87. An example of an External Failure Cost is _______.
A. Warranty claim after product delivery
B. Rework on the shop floor
C. Inspection before shipping
D. Employee training
✅ Answer: A. Warranty claim after product delivery
Q88. Which metric best indicates process consistency?
A. Standard deviation
B. Mean value
C. Sample size
D. Range
✅ Answer: A. Standard deviation
Q89. The role of data in Six Sigma is to _______.
A. Drive decisions objectively
B. Justify management opinions
C. Replace teamwork
D. Delay projects
✅ Answer: A. Drive decisions objectively
Q90. The “Control” phase deliverables typically include _______.
A. Control plan and standard operating procedures
B. Project charter and VOC analysis
C. CTQ Tree
D. Pareto Analysis
✅ Answer: A. Control plan and standard operating procedures
Q91. What does a Process Owner ensure in Six Sigma?
A. Sustaining the improvements achieved
B. Providing statistical tools
C. Allocating funds
D. Conducting project reviews only
✅ Answer: A. Sustaining the improvements achieved
Q92. Which of these best represents the philosophy behind Six Sigma?
A. Continuous improvement through data and discipline
B. Employee satisfaction programs
C. Marketing optimization
D. Product design innovation only
✅ Answer: A. Continuous improvement through data and discipline
Q93. The term “tolerance” in quality refers to _______.
A. Acceptable range of variation
B. Defect frequency
C. Mean shift
D. Process delay
✅ Answer: A. Acceptable range of variation
Q94. A project scope statement defines _______.
A. Boundaries of inclusion and exclusion
B. Process inputs only
C. Employee roles
D. Financial budgets
✅ Answer: A. Boundaries of inclusion and exclusion
Q95. A high sigma level process implies _______.
A. Greater process capability and consistency
B. More customer complaints
C. Increased costs
D. Lower customer satisfaction
✅ Answer: A. Greater process capability and consistency
Q96. Six Sigma originated from which organization?
A. Motorola
B. Toyota
C. IBM
D. GE
✅ Answer: A. Motorola
Q97. The 3.4 DPMO benchmark allows for _______.
A. 99.99966% accuracy
B. 95% accuracy
C. 80% performance
D. 90% confidence
✅ Answer: A. 99.99966% accuracy
Q98. Statistical validation of improvements is part of the _______ phase.
A. Improve
B. Define
C. Measure
D. Control
✅ Answer: A. Improve
Q99. The main function of a Tollgate Review is to _______.
A. Verify completion of phase deliverables
B. Reassign project team
C. Collect VOC data
D. Design experiments
✅ Answer: A. Verify completion of phase deliverables
Q100. Six Sigma primarily reduces _______.
A. Process variation
B. Employee count
C. Marketing spend
D. Profit margin
✅ Answer: A. Process variation
Q101. The methodology that extends Six Sigma into design is called _______.
A. Design for Six Sigma (DFSS)
B. Lean Six Sigma
C. PDCA
D. TQM
✅ Answer: A. Design for Six Sigma (DFSS)
Q102. Which of the following combines Lean principles with Six Sigma?
A. Lean Six Sigma
B. Agile Six Sigma
C. Kaizen Sigma
D. Total Sigma Management
✅ Answer: A. Lean Six Sigma
Q103. Which Six Sigma metric measures process yield?
A. Rolled Throughput Yield (RTY)
B. Mean Absolute Deviation
C. Net Promoter Score
D. Regression Coefficient
✅ Answer: A. Rolled Throughput Yield (RTY)
Q104. In Six Sigma, VOC translates to CTQ through _______.
A. CTQ Tree
B. Regression Equation
C. Histogram
D. Scatter Plot
✅ Answer: A. CTQ Tree
Q105. A control plan ensures that _______.
A. Process improvements are maintained over time
B. New processes are implemented
C. Projects are redefined
D. Variations are ignored
✅ Answer: A. Process improvements are maintained over time
Q106. Six Sigma primarily uses which type of data?
A. Quantitative and Qualitative
B. Emotional
C. Random
D. Financial only
✅ Answer: A. Quantitative and Qualitative
Q107. Which statistical concept underpins Six Sigma performance?
A. Normal distribution
B. Exponential distribution
C. Binomial sampling
D. Poisson probability only
✅ Answer: A. Normal distribution
Q108. The best way to prioritize multiple CTQs is to use _______.
A. Pareto Analysis
B. Fishbone Diagram
C. Histogram
D. Regression
✅ Answer: A. Pareto Analysis
Q109. The Six Sigma Belt hierarchy resembles a _______.
A. Martial arts system
B. Financial pyramid
C. Marketing funnel
D. Decision tree
✅ Answer: A. Martial arts system
Q110. The philosophy of Six Sigma is rooted in _______.
A. Continuous improvement and data-driven excellence
B. Speed over quality
C. Cost-cutting without measurement
D. Random inspection
✅ Answer: A. Continuous improvement and data-driven excellence
Six Sigma questions, Six Sigma DMAIC quiz, Six Sigma MCQs, Six Sigma roles and belts, CTQ VOC VOB, Cost of Quality, COPQ examples, Define Measure Analyze Improve Control, process capability, defect rate, Lean Six Sigma
