Top 25 Six Sigma Interview Questions and Answers 2022

Efficient operations management is vital across different industry verticals. Its requirement is also changing and evolving towards quality control which is more data-driven than before. Here, Six Sigma satisfies the growing demand, and no doubt, a certification in Six Sigma can help the candidate stand out in today's job market.

There is an ocean of opportunities from several top-notch companies across the globe. According to research, Six Sigma has a market share of over 27.7%. Hence, you choose to move ahead in your career development with Six Sigma.

If you are looking for Six Sigma interview questions for freshers/experience, then you are at the right spot. This article will be vocal about how a Six Sigma accreditation holder can answer the trickiest and most accessible questions you know subtle method that impresses your recruiters and authorities responsible for your future.

Q1. What is Six Sigma and Why is it Called So?

The basic and fundamental question a recruiting manager can ask is your expertise and knowledge on Six Sigma. Therefore, in simple terms, you can define the methodology as a technique that a company leverages to enhances its business process and quality.

By leveraging Six Sigma, companies can maximize performance and minimize process variation - helping businesses to minimize defects, boost profits, improve employee morale, and ameliorate product quality.

For the question - why it's called Six Sigma, you can answer:

To achieve the methodology, the processes of a company require to maintain their defects maximum to 3.4 DPMO, which is otherwise strenuous to achieve.

(DPMO - Defects Per Million Opportunities)

Q2. Define Few Critical Principles of Six Sigma?

• Enhancing of processes
• Prime focus on customer demands
• Effective managing of cross-functional teams
• Relying on statistical analysis to determine the best possible methods of working and finding root causes of probable issues.
• Formulate process flexibility

Q3. Define Two Sub-methodologies of Six Sigma?

1. Define, Measure, Analyse, Improve, and Control (DMAIC) - A method leveraged for existing processes that are lacking behind the features and require gradual enhancement.
2. Define, Measure, Analyse, Design, and Verify (DMADV) - An approach leveraged to create new products/services that match the Six Sigma quality. In case a business requires more than gradual enhancement, the DMADV process can be used.

Q4. Name Some Quality Management Tools in Six Sigma?

• CTQ Tree
• 5S
• Value Stream Mapping
• Cost-benefit Analysis
• COPIS Analysis
• SIPOC Analysis

Q5. Name a Tool that Visualizes the Possible Causes of a Given Issue?

A tool that helps in conceptualizing the possible causes of a given issue/problem is Ishikawa diagram.

Q6. What are the Different Variations Used in Six Sigma?

1. Mean: This measurement is considered only for a certain application and the values are estimated. Hence, within this process, the variations are measured and compared using average mathematics techniques.
2. Median: This method is done by determining the lowest and highest values and then dividing the value by 2. Within this process, the variations are estimated and compared by taking the midpoint of the set data range.
3. Range: It takes into account the largest and smallest values for a certain range of data.
4. Mode: This is nothing but the most occurred values in a given set of data range.

Q7. What is COPQ in Six Sigma?

Cost of Poor Quality (COPQ) is the cost caused by generating defects. This cost involves the following guidelines:

• Disposition Costs
• Extra Utility/Material Cost
• Filling the Gap Between Actual and Desired Service/Product Quality
• Loss of Revenue or Sale
• Labor Cost
• Rework Cost

However, COPQ doesn't include detection and prevention cost.

Q8. Who is Responsible for Creating or being a Part of Six Sigma Implementation Team Within a Company?

The designated individuals who are part of the Six Sigma implementation team are:

• Decision-making executives
• Master Black Belts
• Champions
• Green Belts
• Black Belts
• Yellow Belts

Q9. Define Affinity Diagram?

Affinity diagram is a tool leverage to organize ideas into subgroups by having a common relation theme to build solutions after brainstorming. To proceed, we need to have an affinity group who puts their ideas of operative quality and starts the brainstorming session.

The solutions obtained from the members of the group are aligned and segregated into homogeneous groups with an affinity heading on top. In this way, an individual visualizes the solution and list their numbers accordingly.

Q10. State the Difference Between Performance and Load Testing?

Performance Testing

• It is all about having more stress on the system checks and the overall application and system performance during the stress conditions.
• Performance testing being a superset of load testing, the testing includes load and stress testing.

Load Testing

• It is a testing process where the load limit is beyond what the customer demanded. This will help the individual whether the application can handle a specific limit.
• Load testing is about how well the program behaves and how many concurrent users are able to log in without facing any issues.

Q11. What is Cpk and Ppk?

Cpk is process capability index that estimates how close a process is running to its specification limits, relative to the natural process variability.

Ppk is the process performance index that verifies if the model that has been produced from the process is capable of meeting customer needs or CTQs.

Q12. How Six Sigma Benefits a Company and an Individual Taking the Certification?

• Helps the company to minimize the level of errors.
• Works towards the amelioration of quality assurance
• Helps candidate to develop skills and turn them to leaders
• Candidates with Six Sigma certification receives handsome remuneration and promotion compared to non-certified peers
• The process applicable for all the markets and can be executed throughout the business environments
• Work towards the enhancement of business workflow.

Q13. Explain Pareto Chart?

Pareto analysis is the most used tool in Six Sigma for quality improvement. This not only prioritize problems, but define each and every aspect. This chart sets up a clear image of what required to be dome with the problems, keeping in mind the available resources and cost.

With the help of analysis, we can optimize the process require and the cost factor. This helps us to target customer requirements better than the competitors and reach satisfaction with the feedback loop offered by the stakeholders. 

Q14. How to Create a SIPOC Process Map?

Suppliers Input Process Output Customers (SIPOC) is defined as a series of consecutive steps and tasks that are executed promptly to receive a definite output.

The SIPOC process map is vital for determining the following elements:

• How the existing processes are working
• How the processes are changed and enhanced
• How the enhancement is implemented with the next stage of DMAIC.

Q15. What is DFSS in Six Sigma Process?

Define for Six Sigma (DFSS) is a process involved in designing or redesigning the product/service from scratch. One of the cases where the project is following DMAIC methodology goes into the DFSS project because of the designing related tasks.

Q16. What is Lean Six Sigma? What are its Benefits?

Lean Six Sigma is a performance enhancement method that involves eradicating activities that don't add value to the process and reducing variation. This relies on a collaborative team effort and contributes to top-notch quality and customer satisfaction.

Benefits of Lean Six Sigma are:

• Manage larger teams
• Better task prioritization
• Increase team productivity
• Eradicating defects
• Reduce time
• Ensure more efficient business workflow

Q17. Name Some Lean Six Sigma Tools?

• Regression Analysis
• Pareto Chart
• FMEA
• Value Stream Mapping
• Poka-yoke
• Kaizen

Q18. When can the Kaizen Tool be Used?

In situations where we require to implement gradual enhancement, Kaizen serves as the best solution by generating quick solutions to two pressing issues that appear to be critical. This is highly efficient in tackling intensive cross-functional collaboration, and with a swift solution, we can increment enhancement in nearly 3-5 days of execution.

Q19. Explain the Levels of Quality in Six Sigma?

Six Sigma quality levels is a method leveraged to observe and estimate the process quality. At every level of Six Sigma, a number of DPMO are defined. The perfect level of the methodology is achieved at 3.4 DPMO.

The levels of Six Sigma DPMO are:

1. 6,90,000
2. 3,08,537
3. 66,807
4. 6,210
5. 233
6. 3.4

Q20. What Exactly is FMEA in Six Sigma?

Failure Mode and Effect Analysis (FMEA) is leveraged to determine possible risks within the product, process, or design. After determining the risk, individuals can create a risk alleviation plan to overcome them.

Q21. What are the Pros & Cons of Zero Defect?

PROS:

• Eradicates Hidden Costs/Expenses
• Helps in Planning
• Provides Improved Value to the customer

CONS:

• Strenuous to Achieve
• Time-bound and Needs a Proactive Method
• Sound More Abstract to Most of the Organizations
• Outdated Technology

Q22. Tell Us About the Project You Have Worked On?

For this question, you must describe the project and give a summarized and good insight into it. Make sure you describe the project precisely as the recruiting manager may ask for other details related to your project.

Q23. What Factors Did You Consider Before Initiating Your Six Sigma Project?

For this question, list the significant factors that you must have considered before initiating the project. The first and foremost factor any individual would consider is the Process Stability and other factor is Process Capability.

Q24. What Were the Problems You Faced When Working with the Project and How Did You Resolve It?

If you have worked on a project, try recalling minor to major details working on the same and write down some points that are relevant and also some factors that are fundamental in Six Sigma projects. Also ensure that your answer cover the next question which is how did you resolve the issue.

Q25. What is the Kano Model?

It is one of most significant questions on Six Sigma. Kano is a product development technique leveraged to determine VoC and compares the characteristics Vs degree of satisfaction each characteristic deliver.

The technique is invented by Dr. Kano which defines the following:

• Dissatisfying
• Must-Haves
• Customer needs
• Delighters
• Indifferent