Become a Certified Professional

Six Sigma Interview Questions for Basic Level

1. Explain Six Sigma?
Ans:Sigma is a statistically based indicator of variance in a procedure. If the efficiency is 3.4 Defects per
Million Opportunities (DPMO), the Six Sigma procedure is used. Six Sigma is a technique for resolving
problems. This approach can be applied to a framework for identifying and removing the root cause of
defects and the costs associated with them.
Looking for Six Sigma Course? Enroll Now to get a FREE demo on Six Sigma Online Training !

2. Explain Six Sigma Levels?

Ans:It is a technique and collection of methods for assessing the consistency of an operation. It shows how
effectively the business operation is managed. When the process's accuracy is less than 3.4 defects per
million opportunities, you have reached the Six Sigma mark.
The number of defects per million that are appropriate for each Sigma standard is listed below:
Sigma level Defects per million opportunities

 690,000
 308,537
 66,807
 6,210
 233
 3.4

3. What are the different variations that are used in the Six Sigma
process?
Ans: The various types of variations used in the six sigma method are as follows:
Mean: This calculation is only taken into account for a specific application, and the results are measured.
So, in this method, the differences are calculated and compared using standard mathematical techniques.
Median: This procedure begins with determining the highest and lowest values, then dividing the result by
two. The variations are evaluated and compared in this method by taking the midpoint of the data set
collection.
Range: As the name suggests, it considers the highest and lowest rates for a given date range.
Mode: The most frequently occurring values in a given data set spectrum are known as a mode.

4. What are the different six sigma methodologies available?

Ans: The following are two six sigma sub methodologies that the teams should concentrate on:

 DMAIC: It stands for ( Define, Measure, Analyze, Improve, Control)

 DMADV: It stands for ( Define, Measure, Analyze, Design, Verify)

5. What is COPQ?
Ans:
  Cost of production quantity
 Cost of poor quality
 Cost of production quality
 Cost of Poor quantity

If a product is not made to the highest standard, it incurs the expense of low production. If all of the
systems and products produced are ideal, the COPQ will disappear.

6. What are the three key elements for six sigma process
improvement?
Ans: The three critical elements for six sigma process improvement are as follows:
Customers: We must specify all possible metrics so that attributes such as on-time delivery, customer
satisfaction, pricing, service, and transaction processing operations are crystal clear. It is crucial, and one
must ensure that it is taken care of.
Process: This is a crucial part of implementing the Six Sigma method. Any customer will seek out a high-
quality product. As six sigma process implementers, we must take special care to consider the process
from the consumer's viewpoint.
Employees: Finally, to have a stable six sigma process execution, all company employees must be
included and given the ability to develop their skill set.

7. Which of the following tools helps in visualizing series of causes to

an effect?
Ans:

 Cause and Effect Matrix

 Correlation Diagram
 Ishikawa Diagram
 Value Stream Mapping

The Ishikawa diagram, also known as the fishbone diagram, aids in the visualization of several possible
causes for a given problem.

8. Name some Lean Six Sigma tools.

Ans: Some Lean Six Sigma tools are:

 Kaizen.
 Poka-yoke.
 FMEA.
 Value Stream Mapping.

9. Which analysis helps to prioritize customer requirements?

Ans:

 Kaizen
 Kano
 Control charts
  Poisson

When consumer needs are known, Kano analysis may help prioritise them. In six sigma, Kano analysis is
used to describe the DMAIC step.

10. What is the difference between Cpk and Ppk?

Ans:Process capability index is abbreviated as Cpk. It determines how close a process is to meeting the
design limits in comparison to the process' normal variability.
Ppk, on the other hand, is a process performance index that determines whether or not the sample provided
by the process is capable of meeting Customer [Link] Training

Six Sigma Interview Questions for Intermediate Level

11. Which of the following tasks should a Green Belt execute first in a
standard Measure Phase?
Ans:

 Stability
 Capability
 MSA
 Normality

There is more numeric and data analysis in the measured process. The MSA (measurement system
analysis) can determine how much variance in the data the measuring system has produced. MSA is a
time-consuming process.

12. Explain what you mean by FEMA?

Ans: The term FEMA refers to the Measure Phase's final segment.
So, in a nutshell, it promotes the cause of avoiding defects from occurring in the first place. So, in a way,
being cautious and ensuring that the process is free of known defects.
The probable defects are usually included in the FEMA process and are rated in three different ways:

 The possibility that something would go wrong.

 The potential to identify a defect.
 Severity of the defect

If the defect severity is deemed minimal, the user may not need to spend any time validating the procedure.

13. What is the main difference between Lean and Six Sigma?
Ans:
To minimise waste, Six Sigma employs the DMAIC approach. Lean, on the other hand, employs the
following seven steps:

1. Overproduction: This happens when products are created but there is no one to
purchase them.
 2. Waiting: There is little value added to the project if there is a time gap in and phase of
production.
3. Transport: When products are shipped in an inefficient manner, this occurs.
4. Motion: This one refers to poor professional ethics and workers engaging in inefficient
practises in between tasks.
5. Over-processing: When you take too long to create a product, this happens.
6. Inventory: This type of waste happens when the inventory volume is too high and you
have too much work in progress.
7. Defects: This is the amount of time workers spent finding and correcting production
errors.

14. What is the difference between load test and performance testing?
Ans: The following is the distinction between load testing and performance testing:
Load Testing:
Load testing is simply a phase in which the load limit exceeds the client's [Link] will help us
figure out whether the program can support a certain amount of data.
Load checking determines how well an application or service behaves and how many concurrent users can
log in without experiencing any issues.
Performance Testing:
Performance testing entails putting more emphasis on system tests as well as the overall programme and
system performance under stress. Performance testing is, in several ways, a subset of load testing.
Load and stress testing are also part of the performance testing process.

15. Explain what is meant by Lean Six Sigma?

Ans: A lean six sigma approach, on the other hand, is a methodology that entails the whole team's
commitment to bring about progress in terms of efficiency enhancement by finding waste and reducing
variation.
As a result, they work in conjunction with the lean six sigma method to remove eight different types of
waste:

 Defects
 Overproduction
 Transportation
 Inventory
 Motion
 Extra Processing

These are only a few examples of areas where the process flow can be improved and optimised by
improving the whole process flow.

16. What are Function Points In Project Management?

Ans:
A function point is a measuring unit used to express the amount of business functionality provided by an
information system.
There is an association of consumers of software metrics called the International Function Point Users
Group, which is headquartered in the United States. Analysis of Function Points The IFPUG practical size
measuring system uses feature points as a unit of measurement.
The IFPUG FSM is one of the ISO specifications for technically sizing functionality that is currently in
use.

17. What is the main role of a Master black belt in terms of

implementing a six sigma team?
Ans: The main role of Master black belt holder of the six sigma process is vital for an organization
because most organizations don’t start with a concrete six sigma process.
So building up the practice and making sure that they are in line with the standards is very important. So
the core process is initiated and mentored if necessary to the users who are part of the six sigma process
implementation team.

18. What is the Top-down approach in the six sigma process?

Ans: One of the processes used in Six Sigma implementation is the top-down method. As a result, this
practise is normally in accordance with the company's policy and consumer requirements.
However, one of the main drawbacks is that the variety is extremely wide, making it difficult to complete
in a reasonable period of time.
Six sigma programs are usually finished in three to six months, according to industry guidelines.

19. What are the three steps for Root cause analysis?
Ans: The three steps for Root cause analysis is:
Open step: This is the first move, in which all members of the team are assembled and a brainstorming
session on all potential possibilities is held.
Narrow step: Considering our current sigma results, all potential theories and possibilities are narrowed
down to some degree during this process.
Close step: During this process, the project team will confirm all of the reasons for the current sigma
performance that have been narrowed down.

20. Explain what is a Pareto principle?

Ans: The data is shown using a Pareto map, which is built on the Pareto principle's underlying definition.
It's known as the 80/20 law.
Using this rule would allow the team to concentrate on individual projects and problems that could have a
larger effect if not addressed early on.

Subscribe To Our Subscribe

Six Sigma Interview Questions for Advanced Level

21. When is the FMEA process generally performed?
Ans:

 Begin throughout the design concept stage and continue throughout the project.
 After the production tool has been authorized.
 It comes to an end as soon as the conceptualization is completed.
 This was implemented in the design phase.
FMEA (failure mode and effect analysis) is a systemic method/approach for identifying potential failures
in architecture, production or assembly processes, or a product or service. This procedure starts with the
project's conception and continues throughout the project's lifecycle.

22. What is a data collection plan?

Ans: A data collection plan is nothing more than a strategy for gathering the requisite information. As a
result, the following areas are covered in this program.

 The data collection strategy analyses the kind of data that needs to be processed or
obtained.
 What data sources are used to interpret the data in the data collection plan?

As a result, the primary goal of data collection is to get a better understanding of the present procedure and
to depict potential improvements. The following are three main sources from which data can be gathered.
Input: The term "input" refers to the location where data is generated.
Process: The method is made up of implementation phases that take into account considerations such as
performance, time constraints, expense, and defects to enhance the process.
Output: It's a straightforward productivity metric.

22. When a cause-and-effect diagram is used to solve plant problems,

what are the three parts a session is customarily divided into?
Ans:

 Teamwork, cost-effectiveness, efficiency

 Brainstorming, prioritization and plan development
 Teamwork, planning and execution
 Cost-effectiveness, plan development, teamwork.

A cause and effect diagram helps to identify the possible causes and the outcomes of a problem. This is
done is three parts; Brainstorming, prioritization and plan development

23. How to develop a SIPOC process map?

Ans: SIPOC stands for Suppliers Input Process Output Customers.
A process is a series of similar steps and tasks that are carried out in a logical order to produce a particular
outcome.
The following elements must be identified using the SIPOC method map:

 How are the current processes operating?

 How are the processes modified and improved?
 How is the improvement carried out or implemented with the next phases of DMAIC?

24. Explain Key Roles In All Six Sigma Efforts ?

Ans:
The following are the key roles of Six Sigma efforts:
Sponsor: The organisation is led by a business executive.
Champion: Responsible for Six Sigma strategy, deployment, and vision.
Process Owner: Responsible for long-term sustainability gains is the owner of the enhanced process,
product, or service..
Master Black Belts: Coach black belts expert in all statistical tools.
Black Belts: Work on 3 to 5 $250,000-per-year projects; create $1 million per year in value.
Green Belts: Work with black belts on projects.

25. How does the cost of six sigma implementation is estimated by the
organizations?
Ans: The cost of implementing six sigma is calculated in a variety of ways, and a few of the more common
ones are described below:
1. The cost of implementing six sigma should be deducted from the company's own payroll, and the people
who worked full time on this process can be compensated accordingly.
2. This is an informal payroll policy in which people are classified and paid based on tasks such as data
collection, measurements, and conversations with product owners, among other things.
3. This is purely a consultative approach, with consultants being compensated according to the amount of
hours they spent training and mentoring the team.
4. This is an entirely new approach to the six-sigma methodology. The payoff can occur as a result of the
improvisation process.

26. A Six Sigma Green Belt practitioner constructs a control chart to

display a process mean and its outer limits. In such a chart, what does
UCL stand for?
Ans:

 Upper Cycle Length

 Upper Control Limit
 Upper Cycle Limit
 Upper Control Length

Control charts are two-dimensional graphs that show data on the x-axis and time on the [Link]
control limit (UCL), Lower control limit (LCL), and average or centre line of the data are the three
characteristics of a control chart. A three-process control above the standard deviation is the upper control
limit.

27. For a process working at 5 Sigma level, how many opportunities

are considered to lie outside of the specification limits provided by the
customer?
Ans:

 233
 6210
 3.4
 66807
The Sigma 4 standard refers to the average percentage of precision which shows the highest number of
defects per million in a process or device. A 5 sigma level 233 errors per million.

28. In the project development cycle, what would a “Waste” mean?

Ans:

 Time spent on unproductive events

 Time spent on fixing defects
 Time spent on Unproductive resources
 Time spent on unnecessary expenditure

In lean, anything that does not contribute to the final product's functionality is referred to as "Waste." That
is to say, the time spent correcting defects is called waste.

29. What are the benefits of the six sigma process to the organization
and for the individual practicing it?
Ans: The benefits of the six sigma process are as follows:

 Aids the enterprise in reducing mistakes to the point that they can be eliminated.
 Contributes to the improvement of business processes.
 Contributes to the enhancement of Quality Assurance.
 This process can be applied throughout the business environments, applicable for all the
markets.
 Ascertains that it is in compliance.
 Individuals are assisted in developing expertise and becoming leaders.
 Individuals with this experience should be compensated well.
 Quality assurance and quality management.

30. What are the popular myths or misunderstandings about the Six
Sigma process?
Ans: The popular myths or misunderstanding about six sigma process is as follows:

 Six Sigma is a method that focuses solely on defect reduction.

 The Six Sigma method is used in the production and deployment of projects.
 Six Sigma is merely a type of training with no practical implementation.
 Engineering operations cannot be subjected to the Six Sigma process.

Top 20 Six Sigma Interview Questions and

Answers
1. Explain what is Six sigma?
Six sigma is one of the perfect problem-solving methodologies. This process is
applied in most of the organizations and the projects they work in. So using this
process, the organizations can actually understand the root cause of the problem
and also the costs associated to fix the same.

So using this six sigma process, the organization will be able to identify the root
cause of the problem and put in necessary fixes, and also try to reduce the cost
associated with the same by taking precautions that the same mistake or error
doesn’t happen again.

It is measured based on the DPMO factor, i.e. Defect per Million Opportunities.

2. What are the different levels available in Six sigma?

Six sigma is nothing but a process improvement methodology where the root cause
of the errors is identified and ultimately helps in improving the overall process. So
when it comes to the Six Sigma level, one has to check with the DPMO score.

If the accuracy of the process gets to a level where it has only 3.4 defects per million
opportunities. Below, is the list of defects per million that are catered towards a
single level:

 690,000
 308,537
 66,807
 6,210
 233
 3.4

3. What are the different variations that are used in the Six Sigma
process?

The following are the different kinds of variations that are used in the six sigma
process:

Mean: This measurement is actually considered only for a particular application

and the values are calculated. So within this process, the variations are actually
measured and compared using average techniques of mathematics.

Median: This process is initiated by identifying the highest and the lowest values
and then divide the value by 2. Within this process, the variations are actually
measured and compared by taking the midpoint of the data set range.

Range: As the name implies it actually takes into consideration of highest rate and
lowest values for a specific date range.
Mode: Mode is nothing but the most occurred values in a given data set range.

4. So within an organization who are responsible for building or be

a part of the Six Sigma implementation team?

So within an organization, the following roles or designated individuals will be a part

of the six sigma implementation part, they are as follows:

 Executive management, the leaders are responsible for making decisions

 Champions
 Master Black belts
 Black belts
 Green Belts

5. What is the main role of executive leaders or executive

management in terms of implementing the six sigma team?

Well, these are the individuals who will be responsible for driving initiatives to make
sure their product quality and processes are optimized to a profitable level where
the entire team is being productive with fewer operations costs incurred.

So most of the time, the executive leaders will be the CEO or Board of director
members, etc. The main motto of these individuals is to make sure that they deliver
a quality product to the customers and make sure they are satisfied.

6. What is the main role of champions in terms of implementing

the six sigma team?

So champions are more likely senior managers that manage micro teams based on
individual projects they deal with.

So most of the time they promote good aspects of implementing Six Sigma
processes and also do involve coaching and mentoring if needed.

7. What is the main role of a Master black belt in terms of

implementing a six sigma team?

The main role of the Master black belt holder of the six sigma process is vital for an
organization because most organizations don’t start with a concrete six sigma
process.
So building up the practice and making sure that they are in line with the standards
is very important. So the core process is initiated and mentored if necessary to the
users who are part of the six sigma process implementation team.

8. What are the different six sigma methodologies available?

They are two six sigma sub methodologies that are available for the teams to focus
on, they are:

 DMAIC: It stands for ( Define, Measure, Analyze, Improve, Control)

 DMADV: It stands for ( Define, Measure, Analyze, Design, Verify)

9. Explain in detail what is meant by DMAIC six sigma

methodology?

Well, DMAIC stands for Define, Measure, Analyze, Improve, and Control. Within this
process, it is an improvement system for all the existing processes where they
identify whether there needs to be any process improvement and look for it on
regular basis to achieve the ultimate process efficiency.

So basically, this process to execute has 5 different phases where the entire
functional flow or the process is evaluated on different parameters which eventually
results in the optimized process flow for a better and concrete outcome.

10. When was Six Sigma was developed and who was the inventor?

So the six sigma process was developed by Motorola to make sure that their
products are measured in terms of the highest quality and the year it was invented
in 1986.

11. What are the quality management tools and methods that are
used in the Six Sigma process?

They are many third-party tools that can be integrated with the Six Sigma process to
achieve process efficiency. The methods that six sigma follows are:

 DMAIC: Stands for Define, Measure, Analyze, Improve, Control

 DMADV: Stands for Define, Measure, Analyze, Design, Verify

12. What is the difference between load test and performance

testing?

The difference between load testing and performance testing is as follows:

Load Testing:

 Load testing is nothing but a testing process where the load limit is beyond
what the client has required. This would help us understand whether the
application can handle a certain limit.
 Load testing is about how well the application or the program is behaving
and how many concurrent users are able to log in to the application without
any problem.

Performance Testing:

 Performance testing is all about having more stress on the system checks
and also the overall application and system performance during the stress
conditions. In a sense, performance testing is nothing but a superset of the
load test.
 Performance testing includes load testing and as well as stress testing.

13. Explain what is meant by Lean Six Sigma?

Well, a lean six sigma is nothing but a methodology that involves the entire team
effort to bring them in the change in terms of performance improvement by
identifying the waste and the variance reduction.

So in conjunction with the lean six sigma process and eliminates 8 different kinds of
wastes, they are as follows:

 Defects
 Overproduction
 Transportation
 Inventory
 Motion
 Extra Processing

Well, these are few areas where the process flow can be improvised and get
maximum benefits by optimizing the entire process flow.

Related Article: LEAN Questions and Answers

14. What are the benefits of the six sigma process to the
organization and for the individual practicing it?

The benefits of the six sigma process are as follows:

  Helps the organization to reduce to a level where they can eliminate the
errors.
 Works towards improving the business processes.
 Works towards the betterment of Quality Assurance.
 This process can be applied throughout the business environments,
applicable for all the markets.
 Makes sure that it comes under compliance.
 Helps the individuals to build skills and turn them into leaders.
 Have attractive salaries for individuals having this skill.
 Quality assurance and quality management.

15. What is the main difference between lean and six sigma?

The main difference between lean and six sigma is that lean methodology focuses
on waste reduction within a process flow. Whereas, six sigma process focuses
mainly on variation analysis and variance reduction.

16. What are the popular myths or misunderstandings about the

Six Sigma process?

The popular myths or misunderstanding about six sigma process is as follows:

 The Six Sigma process is defined only for reducing defects.

 The Six Sigma process is actually used for the production or deployment of a
project.
 Six Sigma is just training and has no implementation in the day to day life.
 The Six Sigma process cannot be applied to engineering activities.

17. What are the three key elements for six sigma process
improvement?

The three key elements for six sigma process improvement are as follows:

Customers: They are the sole owners of the entire process outcome so we need to
define all possible metrics so that the attributes like on-time delivery, customer
satisfaction, pricing, service, and transaction processing activities should be crystal
clear. It is very important and one has to make sure that all are dealt with.

Process: This is the critical aspect of the Six Sigma process implementation. For any
customer, they would look for a quality product. So as six sigma process
implementers we need to take due care to understand this process from the
customer’s perspective.
Employees: Finally the last thing to have a successful six sigma process
implementation is to include all the employees of the organization and provide
them an opportunity to grow their skill set.

18. What is the Top-down approach in the six sigma process?

The top-down approach is one of the processes within Six Sigma implementation.
So usually this type of approach is in line with the business strategy and the
customer needs.

But it has one of the major disadvantages is that the scope is very broad and at the
same time it is difficult to be executed in a specified amount of time.

As per the industry standards, the six sigma projects are executed and completed in
the time span of 3 to 6 months.

19. How to develop a SIPOC process map?

SIPOC stands for Suppliers Input Process Output Customers.

A process can be defined as a series of consecutive steps and activities that are
executed in a timely manner to get a definite output.

The SIPOC process map is very important for identifying the following elements:

 How the current processes are operating.

 How the processes are modified and improved.
 How the improvement is carried out or implemented with the next phases of
DMAIC.

20. Explain what do you mean by FEMA?

FEMA stands for the Final segment of the Measure Phase.

So basically it promotes the cause of preventing defects before even they occur. So
in a sense being proactive and making sure that are no known defects within the
process.

Within the FEMA process they generally include the possible defects and rate them
accordingly in three different ways, they are:

 The likelihood of something might actually go wrong.

 Ability to detect a defect.
 Defect severity level.
If the defect severity is considered to be low then the user does not have to spend
more time in terms of validating the process.

21. What are the three steps for Root cause analysis?

The three steps for Root cause analysis is:

Open step: This is the initial step where all the team members are gathered
together and do a brainstorming session on all possible scenarios.

Narrow step: During this phase, all the possible explanations and scenarios are
narrowed down to an extent considering our current sigma performance.

close step: During this phase, the project team will validate all the narrowed-down
list of explanations for the current sigma performance.

22. What does DFSS stand for in the six sigma process?

DFSS stands for Define for Six Sigma.

This process is actually involved in designing or redesigning the service or a product

from scratch. One of the cases where the project is following DMAIC methodology
goes into the DFSS project because of the designing related tasks.

Related Article: Difference between Lean and Six Sigma

23. Explain what is a Pareto principle?

A Pareto chart is used to display the data and the tool is based on the underlying
concept of the Pareto principle. It is often called as 80/20 rule.

Using this rule will help the team to focus on specific tasks and issues which might
have a greater impact if they are not looked into at the initial stages.

24. So how does the cost of six sigma implementation is estimated

by the organizations?

Well, the cost of six sigma implementation is estimated by the organization in

different ways and a few of the popular ones are listed below:

1. The cost associated with six sigma implementation can be paid out from the
direct payroll of the company and identify the individuals who were involved
in this process full time and paid accordingly
 2. This is an indirect payroll policy where the individuals are identified and
payout based on the activities like data gathering, measurements, and
discussions with the product owners, etc.
3. This is purely a consultative approach, where the consultants will be paid
based on the number of hours they have to spend to train and mentor the
team
4. This is completely a different approach towards the six sigma process. The
payout can happen based on the process of improvisation.

25. What is a data collection plan?

A data collection plan is nothing but a plan which is used to collect the necessary
data. So within this plan, the following aspects are covered.

 What type of data needs to be collected or gathered is analyzed in the data

collection plan.
 What are the data sources for the data is analyzed in the data collection plan?

So the main reason to collect data is to understand the current process and portray
possible improvement suggestions. The data can be collected from three different
primary sources they are as follows:

Input: input is nothing but where the data is generated.

Process: the process is nothing but the execution steps where the factors like
efficiency, time requirements, cost, defects are taken into consideration for process
improvements.