Six Sigma | Poka Yoke, PUGH Matrix, Pilot Implementation & Validation | 100+ MCQ with Answers
Q1. What is the primary objective of the Improve phase in Six Sigma?
A. To identify process defects
B. To implement solutions that reduce variation and improve performance
C. To collect baseline data
D. To document SOPs
✅ Answer: B. To implement solutions that reduce variation and improve performance
Q2. Which of the following is the first step in the Improve phase?
A. Identifying root causes
B. Selecting improvement projects
C. Generating possible solutions
D. Validating process capability
✅ Answer: C. Generating possible solutions
Q3. In Six Sigma, validated X variables refer to:
A. Possible solutions
B. Proven root causes impacting Y
C. Control limits
D. Noise factors
✅ Answer: B. Proven root causes impacting Y
Q4. The SCAMPER technique is primarily used during:
A. Root cause analysis
B. Solution identification and innovation
C. Process mapping
D. Hypothesis testing
✅ Answer: B. Solution identification and innovation
Q5. The acronym SCAMPER stands for:
A. Simplify, Combine, Adapt, Measure, Plan, Evaluate, Repeat
B. Substitute, Combine, Adapt, Modify, Put to another use, Eliminate, Reverse
C. Standardize, Check, Analyze, Manage, Prevent, Execute, Review
D. Substitute, Compare, Assess, Monitor, Prioritize, Execute, Report
✅ Answer: B. Substitute, Combine, Adapt, Modify, Put to another use, Eliminate, Reverse
Q6. In a hospital process improvement project, introducing AI chatbots for basic patient queries reflects which SCAMPER element?
A. Substitute
B. Combine
C. Put to another use
D. Modify
✅ Answer: C. Put to another use
Q7. Merging patient registration and triage into a single digital step illustrates:
A. Combine
B. Substitute
C. Eliminate
D. Modify
✅ Answer: A. Combine
Q8. Benchmarking helps an organization to:
A. Collect historical defect data
B. Identify best practices and process gaps
C. Calculate Sigma level
D. Validate root causes
✅ Answer: B. Identify best practices and process gaps
Q9. In solution selection, the PUGH Matrix compares alternatives against:
A. Baseline process
B. Control limits
C. Randomized criteria
D. Customer feedback
✅ Answer: A. Baseline process
Q10. The PUGH Matrix uses scores of:
A. Yes or No
B. Positive, Zero, or Negative
C. High, Medium, or Low
D. Weighted percentages
✅ Answer: B. Positive, Zero, or Negative
Q11. The PUGH Matrix assumes:
A. All criteria are equally important
B. All criteria have different weights
C. Solutions are tested experimentally first
D. Only financial metrics are used
✅ Answer: A. All criteria are equally important
Q12. The Weighted Scoring method differs from PUGH Matrix by:
A. Allowing unequal importance across criteria
B. Removing the need for data
C. Ignoring feasibility
D. Using qualitative data only
✅ Answer: A. Allowing unequal importance across criteria
Q13. Which of the following is not a typical criterion in solution selection?
A. Feasibility
B. Cost
C. Implementation time
D. Customer name
✅ Answer: D. Customer name
Q14. Logical justification for a solution may be accepted when:
A. Data is insufficient but reasoning is strong
B. Statistical proof is available
C. Multiple root causes exist
D. Benchmarking is impossible
✅ Answer: A. Data is insufficient but reasoning is strong
Q15. Mistake proofing in Six Sigma is also called:
A. Pareto analysis
B. Poka Yoke
C. Gemba
D. Jidoka
✅ Answer: B. Poka Yoke
Q16. Who developed the Poka Yoke concept?
A. Taiichi Ohno
B. Shigeo Shingo
C. Kaoru Ishikawa
D. Genichi Taguchi
✅ Answer: B. Shigeo Shingo
Q17. The hierarchy of mistake proofing effectiveness is:
A. Detection > Correction > Prevention
B. Correction > Detection > Prevention
C. Prevention > Detection > Correction
D. Correction > Prevention > Detection
✅ Answer: C. Prevention > Detection > Correction
Q18. An example of prevention in Poka Yoke is:
A. Using sensors to detect machine errors
B. Designing a plug that can only fit one way
C. Reworking a defective item
D. Sending alerts after a fault
✅ Answer: B. Designing a plug that can only fit one way
Q19. Counting surgical tools before closing an operation is an example of:
A. Prevention
B. Detection
C. Correction
D. Elimination
✅ Answer: B. Detection
Q20. Designing reversible USB-C plugs represents which level of mistake proofing?
A. Correction
B. Detection
C. Prevention
D. Automation
✅ Answer: C. Prevention
Q21. The Improve phase transitions into:
A. Define
B. Measure
C. Analyze
D. Control
✅ Answer: D. Control
Q22. Pilot implementation is conducted to:
A. Avoid documentation
B. Test a solution on small scale before full rollout
C. Replace analysis phase
D. Finalize SOPs
✅ Answer: B. Test a solution on small scale before full rollout
Q23. Which of the following is not a reason to conduct a pilot?
A. Reduce implementation risk
B. Validate solution effectiveness
C. Eliminate need for data collection
D. Build stakeholder confidence
✅ Answer: C. Eliminate need for data collection
Q24. When can a pilot be skipped?
A. When the solution is complex
B. When sufficient evidence or low risk exists
C. When data is unavailable
D. When management opposes it
✅ Answer: B. When sufficient evidence or low risk exists
Q25. A RACI chart helps in defining:
A. Customer satisfaction
B. Resource budgeting
C. Roles and responsibilities
D. Process variation
✅ Answer: C. Roles and responsibilities
Q26. The acronym RACI stands for:
A. Responsible, Accountable, Consulted, Informed
B. Reliable, Accurate, Consistent, Integrated
C. Report, Analyze, Control, Improve
D. Responsible, Active, Consulted, Integrated
✅ Answer: A. Responsible, Accountable, Consulted, Informed
Q27. Gantt charts are used to visualize:
A. Resource consumption
B. Process defects
C. Implementation timelines
D. Data normality
✅ Answer: C. Implementation timelines
Q28. Which element is crucial in full-scale implementation planning?
A. Eliminating stakeholders
B. Ignoring resistance
C. Defining milestones
D. Skipping validation
✅ Answer: C. Defining milestones
Q29. A solution’s risk assessment should include:
A. Potential barriers and mitigation plans
B. Only financial implications
C. Product cost analysis
D. Customer demographics
✅ Answer: A. Potential barriers and mitigation plans
Q30. Post-implementation validation primarily uses which statistical method?
A. ANOVA
B. T-test
C. Chi-square
D. Regression
✅ Answer: B. T-test
Q31. Comparing new process performance to baseline helps to:
A. Identify new defects
B. Quantify improvement
C. Reduce sampling error
D. Adjust tolerance levels
✅ Answer: B. Quantify improvement
Q32. Process capability improvement is reflected through:
A. Higher Cp and Cpk values
B. Lower Cp and Cpk values
C. Same Cp but higher sigma
D. Reduced VOC
✅ Answer: A. Higher Cp and Cpk values
Q33. If post-implementation order fulfillment time improves from 25 to 17 minutes, it indicates:
A. Negative variance
B. Process improvement
C. Control phase issue
D. Customer defect
✅ Answer: B. Process improvement
Q34. Documentation of SOPs after implementation serves to:
A. Capture standardized best practices
B. Replace training
C. Simplify measurement
D. Close control phase
✅ Answer: A. Capture standardized best practices
Q35. The Mumbai Dabbawala system is considered a:
A. Complex supply chain
B. Highly certain supply chain
C. Unpredictable service model
D. Lean enterprise
✅ Answer: B. Highly certain supply chain
Q36. In the Dabbawala system, a defect is defined as:
A. Late salary payments
B. A dabba delivered to wrong location or delayed
C. Food quality issue
D. Missing tiffin carrier
✅ Answer: B. A dabba delivered to wrong location or delayed
Q37. Less than three wrong deliveries per million opportunities implies:
A. 3 Sigma
B. 4 Sigma
C. 6 Sigma
D. 2 Sigma
✅ Answer: C. 6 Sigma
Q38. The Dabbawala’s solution to color code duplication represents:
A. Elimination of variation
B. Process automation
C. Corrective action
D. Process redesign
✅ Answer: C. Corrective action
Q39. CTQs for Dabbawalas include:
A. Profit margin
B. Delivery accuracy and timeliness
C. Box size
D. Packaging material
✅ Answer: B. Delivery accuracy and timeliness
Q40. Resequencing delivery routes based on lunch times (11:30 vs 1:30) represents:
A. VOC alignment
B. Kaizen
C. Process optimization
D. Poka Yoke
✅ Answer: C. Process optimization
Q41. At Malgudi Hospital, training staff in multiple languages addresses which root cause?
A. Ergonomics
B. Language barrier
C. Currency shortage
D. Equipment failure
✅ Answer: B. Language barrier
Q42. Adding extra printers at counters improves performance by reducing:
A. Waiting time due to equipment bottlenecks
B. Staff wages
C. Defect costs
D. Patient satisfaction
✅ Answer: A. Waiting time due to equipment bottlenecks
Q43. Encouraging card or QR payments at Malgudi Hospital addresses:
A. Ergonomic design
B. Currency availability
C. Process variation
D. SOP compliance
✅ Answer: B. Currency availability
Q44. Displaying doctor schedules in local languages supports:
A. VOC communication
B. Poka Yoke
C. Gemba review
D. Root cause validation
✅ Answer: A. VOC communication
Q45. Ergonomic workstation redesign primarily targets:
A. Human motion waste
B. Machine downtime
C. Process sigma calculation
D. Supplier defects
✅ Answer: A. Human motion waste
Q46. The Improve phase is considered successful when:
A. New SOPs are drafted
B. Root causes are redefined
C. Measurable improvements are validated statistically
D. Team completes documentation
✅ Answer: C. Measurable improvements are validated statistically
Q47. “Reducing waiting time from 25 to 17 minutes” represents improvement in which metric?
A. Lead time
B. Defect rate
C. VOC alignment
D. Sigma level
✅ Answer: A. Lead time
Q48. Which of the following is a quantitative validation tool in the Improve phase?
A. Brainstorming
B. T-test
C. Cause-effect diagram
D. Benchmarking
✅ Answer: B. T-test
Q49. The Improve phase directly supports which Six Sigma goal?
A. Defining project scope
B. Minimizing process variation
C. Documenting roles
D. Enhancing control chart accuracy
✅ Answer: B. Minimizing process variation
Q50. Which Six Sigma tool ensures a chosen solution is practical and effective before scaling up?
A. Pilot study
B. Pareto chart
C. SIPOC
D. Histogram
✅ Answer: A. Pilot study
Q51. During a pilot implementation, the main aim is to:
A. Collect large-scale data for financial reporting
B. Test a solution’s performance under controlled real-world conditions
C. Replace the Analyze phase
D. Create SOPs for staff training
✅ Answer: B. Test a solution’s performance under controlled real-world conditions
Q52. Which of the following best describes a pilot test’s benefit?
A. Reduces the number of stakeholders
B. Allows validation before full investment
C. Replaces the need for control charts
D. Avoids statistical testing
✅ Answer: B. Allows validation before full investment
Q53. A pilot implementation provides:
A. Proof of hypothesis in operational environment
B. Elimination of all risks
C. Replacement for full-scale rollout
D. Guaranteed process improvement
✅ Answer: A. Proof of hypothesis in operational environment
Q54. When a solution is immediately required and low-risk, the team may:
A. Skip the Control phase
B. Skip the Pilot
C. Delay implementation
D. Repeat Analyze phase
✅ Answer: B. Skip the Pilot
Q55. Which tool helps assign ownership of implementation tasks?
A. SIPOC diagram
B. RACI chart
C. Pareto chart
D. Histogram
✅ Answer: B. RACI chart
Q56. “Accountable” in a RACI matrix means:
A. Person doing the work
B. Person approving final deliverables
C. Person giving input
D. Person receiving updates
✅ Answer: B. Person approving final deliverables
Q57. Which of these roles in RACI must be exactly one per task?
A. Responsible
B. Accountable
C. Consulted
D. Informed
✅ Answer: B. Accountable
Q58. What is the primary function of the “Consulted” role in RACI?
A. Provide expertise and feedback
B. Execute assigned work
C. Review the project charter
D. Manage stakeholder communication
✅ Answer: A. Provide expertise and feedback
Q59. Gantt charts assist in tracking:
A. Defects per million opportunities
B. Schedule and progress of implementation tasks
C. Cost-benefit ratio
D. Customer satisfaction trends
✅ Answer: B. Schedule and progress of implementation tasks
Q60. The main difference between pilot and full-scale implementation is:
A. Data collection volume
B. Project charter structure
C. Hypothesis testing method
D. Team composition
✅ Answer: A. Data collection volume
Q61. A successful pilot must demonstrate:
A. Statistically validated improvement
B. Employee satisfaction
C. Minimal cost variance
D. Increased number of defects
✅ Answer: A. Statistically validated improvement
Q62. Before implementing a solution organization-wide, the team must:
A. Validate it with data
B. Announce the improvement publicly
C. Skip risk analysis
D. Remove baseline data
✅ Answer: A. Validate it with data
Q63. Risk mitigation during implementation often involves:
A. Eliminating contingency plans
B. Providing training and incentives to staff
C. Ignoring process documentation
D. Reducing number of milestones
✅ Answer: B. Providing training and incentives to staff
Q64. Full-scale implementation requires resource planning across:
A. Only human resources
B. Human, financial, and technological resources
C. Only financial resources
D. Only stakeholder resources
✅ Answer: B. Human, financial, and technological resources
Q65. Post-implementation data collection mimics which DMAIC phase?
A. Define
B. Measure
C. Analyze
D. Control
✅ Answer: B. Measure
Q66. To validate improvement statistically, the team often uses:
A. Chi-square test for independence
B. T-test comparing before-and-after means
C. ANOVA between projects
D. Regression on unrelated factors
✅ Answer: B. T-test comparing before-and-after means
Q67. A significant p-value (p < 0.05) in the T-test implies:
A. No change occurred
B. Improvement is statistically significant
C. Process capability is lower
D. More sampling needed
✅ Answer: B. Improvement is statistically significant
Q68. Post-implementation sigma level improves when:
A. Defects increase
B. Process variation decreases
C. Process mean drifts
D. Sampling error increases
✅ Answer: B. Process variation decreases
Q69. A Cp value greater than 1.33 typically indicates:
A. Poor capability
B. Capable process
C. Unstable process
D. Excessive defects
✅ Answer: B. Capable process
Q70. The Improve phase typically results in:
A. New project selection
B. Validated and implemented solutions
C. Team dissolution
D. Voice of customer surveys
✅ Answer: B. Validated and implemented solutions
Q71. Documenting new SOPs ensures:
A. Sustainability of improvements
B. Faster project closure
C. Reduction in data analysis
D. Increased project variance
✅ Answer: A. Sustainability of improvements
Q72. Which of the following is not part of solution validation?
A. Statistical testing
B. Capability analysis
C. Control chart review
D. VOC survey
✅ Answer: D. VOC survey
Q73. The final step before Control Phase is:
A. Documenting SOPs and lessons learned
B. Conducting new brainstorming sessions
C. Identifying new Xs
D. Redefining project charter
✅ Answer: A. Documenting SOPs and lessons learned
Q74. The Dabbawala coding error correction is an example of:
A. Root cause analysis
B. Poka Yoke in action
C. Pilot testing
D. Statistical validation
✅ Answer: B. Poka Yoke in action
Q75. The Dabbawala delivery process achieves Six Sigma due to:
A. Continuous training
B. Error-proof coding and sequencing
C. Increased delivery staff
D. Random inspections
✅ Answer: B. Error-proof coding and sequencing
Q76. CTQs for a hospital billing process could include:
A. Invoice clarity and waiting time
B. Number of computers used
C. Staff lunch hours
D. Patient feedback only
✅ Answer: A. Invoice clarity and waiting time
Q77. Reducing clerical movement by reorganizing counters reflects:
A. Ergonomic improvement
B. Statistical sampling
C. VOC reduction
D. Hypothesis validation
✅ Answer: A. Ergonomic improvement
Q78. “Prevention is better than correction” is central to which Six Sigma tool?
A. Histogram
B. Poka Yoke
C. SIPOC
D. Control chart
✅ Answer: B. Poka Yoke
Q79. A checklist used to ensure all steps are followed correctly before machine startup represents:
A. Detection-level Poka Yoke
B. Prevention-level Poka Yoke
C. Correction-level Poka Yoke
D. Redundant activity
✅ Answer: A. Detection-level Poka Yoke
Q80. Which of these is not part of SCAMPER?
A. Substitute
B. Eliminate
C. Adapt
D. Calculate
✅ Answer: D. Calculate
Q81. Using fast-track lanes for minor injuries at a hospital represents:
A. Adapt in SCAMPER
B. Substitute
C. Reverse
D. Combine
✅ Answer: A. Adapt in SCAMPER
Q82. Extending a Fishbone diagram to include possible fixes is part of:
A. Cause analysis
B. Solution brainstorming
C. Benchmarking
D. Mistake proofing
✅ Answer: B. Solution brainstorming
Q83. The key output of Improve phase is:
A. List of validated Xs
B. Implemented solution verified by data
C. SIPOC diagram
D. Process charter
✅ Answer: B. Implemented solution verified by data
Q84. “Logical justification” can be accepted as a solution selection approach when:
A. Statistical validation is unavailable but reasoning is strong
B. Multiple Pugh matrices are inconclusive
C. Data is abundant
D. Control limits are unstable
✅ Answer: A. Statistical validation is unavailable but reasoning is strong
Q85. In a PUGH matrix, the “baseline” typically refers to:
A. Current process state
B. Customer target
C. Supplier benchmark
D. Randomized solution
✅ Answer: A. Current process state
Q86. The primary benefit of a Weighted Scoring Matrix is:
A. Customizing priorities based on business impact
B. Eliminating low-cost options
C. Simplifying process mapping
D. Ignoring qualitative data
✅ Answer: A. Customizing priorities based on business impact
Q87. Assigning equal weights to criteria in a matrix assumes:
A. All factors have equal importance
B. Cost is dominant
C. Subjective bias is reduced
D. Data variability is ignored
✅ Answer: A. All factors have equal importance
Q88. A PUGH matrix uses which type of scoring?
A. Numeric weights
B. +, 0, – signs
C. Yes/No
D. Probability values
✅ Answer: B. +, 0, – signs
Q89. A key principle behind Improve phase is:
A. Identify root causes
B. Reduce variation by controlling Xs
C. Create baseline measures
D. Revalidate CTQs
✅ Answer: B. Reduce variation by controlling Xs
Q90. The Improve phase comes after which stage in DMAIC?
A. Measure
B. Analyze
C. Control
D. Define
✅ Answer: B. Analyze
Q91. “Staff resistance to change” should be addressed under:
A. Risk mitigation plan
B. Measurement system analysis
C. Data collection procedure
D. Regression analysis
✅ Answer: A. Risk mitigation plan
Q92. SOPs are a deliverable of which stage?
A. Analyze
B. Improve
C. Control
D. Define
✅ Answer: C. Control
Q93. Using QR code payment to solve currency shortages represents which SCAMPER approach?
A. Modify
B. Substitute
C. Combine
D. Put to another use
✅ Answer: B. Substitute
Q94. A reduction in DPMO (Defects per Million Opportunities) indicates:
A. Process variation increased
B. Process capability improved
C. Sampling size reduced
D. Measurement error increased
✅ Answer: B. Process capability improved
Q95. A process improved from 3 Sigma to 4 Sigma implies:
A. Defect rate increased
B. Variation reduced
C. Mean shifted
D. Data non-normality
✅ Answer: B. Variation reduced
Q96. The main output metric of Improve phase is:
A. Validated performance improvement
B. VOC summary
C. Root cause verification
D. Process mapping
✅ Answer: A. Validated performance improvement
Q97. Which of the following statements about pilot testing is true?
A. It guarantees full success of rollout
B. It reveals practical issues before scaling
C. It replaces the Analyze phase
D. It focuses on defect prevention only
✅ Answer: B. It reveals practical issues before scaling
Q98. During pilot execution, feedback loops help in:
A. Refining solutions based on real-time results
B. Extending project duration
C. Avoiding statistical checks
D. Reducing communication
✅ Answer: A. Refining solutions based on real-time results
Q99. After solution implementation, improved process data should be compared against:
A. VOC benchmarks
B. Baseline metrics
C. Competitor standards
D. Six Sigma handbooks
✅ Answer: B. Baseline metrics
Q100. The transition from Improve to Control phase occurs only after:
A. SOPs and control plans are finalized
B. Root causes are listed
C. Project charter is revised
D. Pilot study fails
✅ Answer: A. SOPs and control plans are finalized
Q101. The Improve phase’s contribution to organizational excellence is through:
A. Sustained cost reduction and efficiency gains
B. Hiring new teams
C. Continuous project creation
D. Increased documentation
✅ Answer: A. Sustained cost reduction and efficiency gains
Q102. A solution’s success is determined by:
A. Statistical significance + Practical feasibility
B. Team consensus
C. Customer reviews
D. Benchmark similarity
✅ Answer: A. Statistical significance + Practical feasibility
Q103. Which phase verifies the “Y = f(X)” relationship improvement?
A. Define
B. Analyze
C. Improve
D. Control
✅ Answer: C. Improve
Q104. Which document summarizes key learnings post-implementation?
A. Lessons Learned Register
B. Process Map
C. VOC Matrix
D. Pareto Table
✅ Answer: A. Lessons Learned Register
Q105. What is the main focus when validating improvement?
A. Proof that implemented solution impacted the critical Y metric
B. Collecting more CTQs
C. Redefining scope
D. Training staff on root cause tools
✅ Answer: A. Proof that implemented solution impacted the critical Y metric
Q106. Which statistical test is most common for comparing means before and after improvement?
A. Two-sample T-test
B. F-test
C. Chi-square test
D. Mann-Whitney test
✅ Answer: A. Two-sample T-test
Q107. If a process change reduces defects but increases cost, selection depends on:
A. PUGH Matrix scoring
B. VOC feedback
C. Team voting
D. Root cause diagram
✅ Answer: A. PUGH Matrix scoring
Q108. In Six Sigma, improvement validation without data is considered:
A. Subjective
B. Reliable
C. Validated
D. Statistically sound
✅ Answer: A. Subjective
Q109. “Continuous process improvement” beyond DMAIC aligns with:
A. Kaizen philosophy
B. Control charting
C. Cost of Poor Quality
D. Process benchmarking
✅ Answer: A. Kaizen philosophy
Q110. In a healthcare Six Sigma project, training multilingual staff improves:
A. Voice of Customer alignment
B. Control limits
C. Sample size
D. Variance testing
✅ Answer: A. Voice of Customer alignment
Q111. Process improvement is sustainable only when:
A. Changes are standardized and monitored
B. Teams are dissolved post-project
C. Baseline data is erased
D. Documentation is skipped
✅ Answer: A. Changes are standardized and monitored
Q112. Which deliverable officially closes the Improve phase?
A. Validated improvement results report
B. CTQ matrix
C. Pareto chart
D. VOC survey form
✅ Answer: A. Validated improvement results report
Q113. Which of the following ensures control of new process variations?
A. Control charts and SOPs
B. Pilot reports
C. VOC tables
D. SIPOC updates
✅ Answer: A. Control charts and SOPs
Q114. The Improve phase often interacts with which department for feasibility?
A. HR
B. Finance and Operations
C. Legal
D. Marketing
✅ Answer: B. Finance and Operations
Q115. Six Sigma improvement sustainability depends on:
A. Continuous monitoring and feedback
B. Frequent project restarts
C. Avoiding data analysis
D. Ignoring VOC
✅ Answer: A. Continuous monitoring and feedback
Q116. Which data pattern shows successful improvement?
A. Reduced mean and reduced variation
B. Increased mean and variation
C. Constant mean, higher variation
D. Random fluctuations
✅ Answer: A. Reduced mean and reduced variation
Q117. What key deliverable bridges Improve and Control phases?
A. Control plan
B. Baseline data
C. Project charter
D. CTQ matrix
✅ Answer: A. Control plan
Q118. A Gantt chart showing overlapping tasks helps:
A. Optimize resource utilization
B. Increase project duration
C. Introduce new CTQs
D. Replace pilot test
✅ Answer: A. Optimize resource utilization
Q119. Using preventive design in equipment to avoid errors is called:
A. Jidoka
B. Poka Yoke
C. Heijunka
D. Kanban
✅ Answer: B. Poka Yoke
Q120. The success of the Improve phase is measured by:
A. Quantifiable, validated, and sustained process improvements
B. Team satisfaction
C. Reduced documentation time
D. Number of brainstorming ideas
✅ Answer: A. Quantifiable, validated, and sustained process improvements
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