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 The ASQ Certified
Six Sigma Yellow Belt
Handbook
 The ASQ Certified
Six Sigma Yellow Belt
Handbook

Second Edition

Govind Ramu

ASQ Quality Press

Milwaukee, Wisconsin
Published by ASQExcellence, Milwaukee, WI

Produced and distributed by Quality Press, ASQ, Milwaukee, WI

© 2022 by ASQExcellence

Publisher’s Cataloging-in-Publication Data

Names: Ramu, Govind, editor.

Title: The ASQ certified Six Sigma yellow belt handbook , second edition /
Govind Ramu, editor.
Description: Includes bibliographical references and index. | Milwaukee, WI:
Quality Press, 2022.
Identifiers: LCCN: 2022933438 | ISBN: 978-1-952236-19-8 (hardcover) |978-1-952236-20-4 (epub)
Subjects: LCSH Six sigma (Quality control standard)—Handbooks, manuals, etc. |
Production management—Handbooks, manuals, etc. | Quality control—Statistical
methods—Handbooks, manuals, etc. | BISAC BUSINESS & ECONOMICS / Quality
Control | STUDY AIDS / Professional
Classification: LCC TS156.17.S59 R36 2022 | DDC 658.5/620218—dc23

No part of this book may be reproduced in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of the
publisher.

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Printed in the United States of America

26 25 24 23 22 GP 7 6 5 4 3 2 1
 I thank my mom, Vasantha, for her unconditional love and encouragement. My dad, Ramu,
would have been so proud to see this book come out. The morals and principles that he taught
me keep me grounded. Thanks to my wife, Anitha, and my children, Vibha and Vivek, for their
patience and sacrifice of countless evenings and weekends. Without their support, this book
would not have been possible.
 Table of Contents

List of Figures and Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

Online Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii
Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix
Introduction: The ASQ Certification Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi

Part I Six Sigma Fundamentals

Chapter 1 Six Sigma Foundations and Principles . . . . . . . . . . . . . . . . . . . . . . . . . 2
Purpose of Six Sigma: Reducing Variation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Methodology (DMAIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Evolution of Six Sigma from Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Value of Six Sigma to the Organization as a Whole . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 2 Lean Foundations and Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Purpose of Lean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lean Methodologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Value of Lean to the Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Chapter 3 Six Sigma Roles and Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . 28
Chapter 4 Team Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Types of Teams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Stages of Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Decision-Making Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Communication Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Chapter 5 Quality Tools and Six Sigma Metrics . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Quality Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Six Sigma Metrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Part II Define Phase

Chapter 6 Project Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Voice of the Customer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Project Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Stakeholder Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Process Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Supply Chain Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

vii
viii Table of Contents

Chapter 7 Project Management (PM) Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Project Charter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Communication Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Project Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Project Management Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Phase Reviews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Part III Measure Phase

Chapter 8 Basic Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Chapter 9 Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Data Collection Plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Qualitative and Quantitative Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Data Collection Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Chapter 10 Measurement System Analysis (MSA) . . . . . . . . . . . . . . . . . . . . . . . . 104
MSA Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Gauge Repeatability & Reproducibility (GR&R) . . . . . . . . . . . . . . . . . . . . . . . . . 105

Part IV Analyze Phase

Chapter 11 Process Analysis Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Lean Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Failure Mode and Effects Analysis (FMEA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Chapter 12 Root Cause Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5 Whys or Why-Why Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Process Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Force Field Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Matrix Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Chapter 13 Corrective Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Corrective Action (CA) Versus Preventative Action (PA):
Requirements of an Effective CA System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Anatomy of a Corrective Action Plan (3WI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
What Is Not a Corrective Action Plan? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Corrective Action Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Chapter 14 Preventive Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Preventive Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Chapter 15 Data Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Basic Distribution Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Common and Special Cause Variation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Chapter 16 Correlation and Regression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Correlation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Regression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Chapter 17 Hypothesis Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
 Table of Contents ix

Part V Improve and Control Phases

Chapter 18 Improvement Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Kaizen and Kaizen Blitz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Plan-Do-Check-Act (PDCA) Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Cost-Benefit Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Chapter 19 Control Tools and Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Control Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Control Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Document Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Part VI Appendices
Appendix A ASQ Code of Ethics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Appendix B ASQ Certified Six Sigma Yellow Belt (CSSYB)
Body of Knowledge (2022) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Appendix C Control Limit Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Appendix D Constants for Control Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Appendix E Areas under Standard Normal Curve . . . . . . . . . . . . . . . . . . . . . . . . 199
Appendix F Binomial Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Appendix G Values of the t-Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Appendix H Acronym List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
 List of Figures and Tables

Part I
Table 1.1 Mapping of PDCA with Six Sigma DMAIC model . . . . . . . . . . . 4
Table 1.2 Six Sigma tools overview by stage . . . . . . . . . . . . . . . . . . . . . . 5
Table 1.3 Approaches to quality over the years . . . . . . . . . . . . . . . . . . . . . . 7
Figure 2.1 Common symbols used in value stream mapping . . . . . . . . . . . 15
Figure 2.2 Value stream map example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 2.3 The 5S cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 2.4 5S workplace scan diagnostic checklist . . . . . . . . . . . . . . . . . . . . . 19
Figure 2.5 The 7S adaptation (Hirano) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 2.6 Visual factory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 2.7 Examples of mistake proofing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 2.8 A sea of inventory often hides unresolved problems . . . . . . . . . 25
Figure 2.9 C-shaped manufacturing cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 3.1 Typical large Six Sigma organization . . . . . . . . . . . . . . . . . . . . . . . 29
Table 3.1 Typical Six Sigma roles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Table 4.1 Common negative team dynamics and potential
countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 4.1 Multivoting ranked approach example . . . . . . . . . . . . . . . . . . . . . 48
Figure 4.2 Multivoting weighted approach example . . . . . . . . . . . . . . . . . . . 48
Table 5.1 Tools across DMAIC phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 5.1 Pareto chart of final assembly inspection defect codes . . . . . . . 54
Figure 5.2 Empty cause and effect diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 5.3 Cause and effect diagram after a few steps of a
brainstorming session . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 5.4 High-level flowchart for an order-filling process . . . . . . . . . . . . 56
Figure 5.5 Basic flowchart for replacement of a product under warranty . . 57
Figure 5.6 Run chart analysis (using statistical software) . . . . . . . . . . . . . . . 58
Figure 5.7 Example of a check sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

xi
xii List of Figures and Tables

Figure 5.8 Scatter diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Figure 5.9 Histogram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
–
Figure 5.10 Example of X and R control chart . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Table 5.2 Examples of metrics by Six Sigma stage . . . . . . . . . . . . . . . . . . . . 63
Figure 5.11 Traditional quality cost curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Part II
Figure 6.1 Map to the entries for the QFD matrix . . . . . . . . . . . . . . . . . . . 69
Figure 6.2 Sequence of QFD matrices for product, part, and
process planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Table 6.1 Risk analysis table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 6.3 A format for SWOT analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 6.4 Stakeholder analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 6.5 Process diagram/model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 6.6 Basic SIPOC diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 7.1 Example of an activity network diagram . . . . . . . . . . . . . . . . . . . 84
Figure 7.2 Example of an affinity diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 7.3 Example of a prioritization matrix . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 7.4 Example of a relationship matrix . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 7.5 Example of a tree diagram showing a fault tree
(used to study defects and failures) . . . . . . . . . . . . . . . . . . . . . . . . 88

Part III
Figure 8.1 Example of a data set as illustrated by a frequency
distribution, individual plot, histogram, and probability plot . . 94
Table 8.1 Summary of descriptive measures . . . . . . . . . . . . . . . . . . . . . . . . . 95
Table 9.1 Data collection plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Table 9.2 Coding—decoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 10.1 Gage repeatability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Figure 10.2 Gage reproducibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Figure 10.3 Example GR&R analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Figure 10.4 GR&R report using statistical software . . . . . . . . . . . . . . . . . . . . . 107
Figure 10.5 Sources of measurement variation . . . . . . . . . . . . . . . . . . . . . . . . . 108

Part IV
Table 11.1 Value-added vs. non-value-added . . . . . . . . . . . . . . . . . . . . . . . . . 113
Table 11.2 Steps in performing a design or process FMEA . . . . . . . . . . . . . . 116
 List of Figures and Tables xiii

Figure 11.1 A typical risk action plan Gantt chart . . . . . . . . . . . . . . . . . . . . . . 118

Figure 11.2 Example FMEA reporting and RPN chart . . . . . . . . . . . . . . . . . . 119
Figure 11.3 A typical top-level management review report for
FMEA progress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Figure 12.1 Symbols commonly used in flowcharts and process maps . . . . 124
Figure 12.2 Basic flowchart for replacement of a product under warranty . . 125
Figure 12.3 Cross-functional or swim lane flowchart . . . . . . . . . . . . . . . . . . . 126
Figure 12.4 Prioritization matrix example: determine the most
suitable software package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Table 13.1 Scenarios: correction and corrective action . . . . . . . . . . . . . . . . . . 132
Figure 15.1 Various populations and sampling distributions of
the mean for selected sample sizes . . . . . . . . . . . . . . . . . . . . . . . . . 138
Figure 15.2 Normal distribution (bell) curve . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Figure 15.3 Normal probability density function and cumulative
density function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Table 15.1 Sample versus population notations . . . . . . . . . . . . . . . . . . . . . . . 139
Figure 15.4 Skewed distributions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Figure 15.5 Bimodal distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Table 15.2 Formula, mean, and variance of certain distributions . . . . . . . . 142
Figure 15.6 Binomial distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Figure 15.7 Binomial distribution using Microsoft Excel . . . . . . . . . . . . . . . . 144
Figure 15.8 Average shifting, variation stable . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Figure 15.9 Average stable, variation changing . . . . . . . . . . . . . . . . . . . . . . . . 146
Figure 15.10 Average shifting, variation changing . . . . . . . . . . . . . . . . . . . . . . 147
Figure 15.11 Average stable, variation stable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Table 16.1 Examples of dependent and independent variables. . . . . . . . . . . 150
Figure 16.1 The four types of correlations in scatter plots . . . . . . . . . . . . . . . 150
Figure 16.2 CORREL function in Microsoft Excel . . . . . . . . . . . . . . . . . . . . . . 151
Table 16.2 Temperature viscosity experiment . . . . . . . . . . . . . . . . . . . . . . . . . 153
Figure 16.3 Regression dialog box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Figure 16.4 Regression data analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Figure 16.5 Simple regression results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Table 17.1 Error matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Figure 17.1 One-tail test: (a) right-tailed test and (b) left-tailed test . . . . . . . 158
Figure 17.2 Two-tail test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Figure 17.3 Power curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
xiv List of Figures and Tables

Part V
Figure 18.1 Meaning of “kaizen” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Figure 18.2 Shewhart cycle (1939) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Figure 18.3 Japanese PDCA cycle (1985) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Figure 18.4 Deming wheel (1950) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Figure 18.5 PDSA cycle and model for improvement (1991, 1994) . . . . . . . . . 168
Figure 18.6 Cost of poor quality (COPQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Figure 18.7 Modern quality cost curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Figure 19.1 A sample control plan template . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Figure 19.2 An example control plan—first page . . . . . . . . . . . . . . . . . . . . . . . 177
Figure 19.3 An example control plan—second page . . . . . . . . . . . . . . . . . . . . 178
–
Figure 19.4 X and R control chart example with data plotted . . . . . . . . . . . . 182
Figure 19.5 Example of a p-chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Table 19.1 Change communication (manufacturing) . . . . . . . . . . . . . . . . . . . 186
Table 19.2 Change communication (service) . . . . . . . . . . . . . . . . . . . . . . . . . . 186
 Online Contents

ASQ certification materials

ASQ webinars
History of quality
Simulated exam—Note that these questions are not the questions
that will appear on the exam. The sample questions are intended to
represent the style of the exam questions and are offered for practice.
Tools and templates
Useful publications
Worked-out examples

Visit https://asqassets.widencollective.com/portals/svdfbllp/(H1493)SupplementalFiles
-TheCertifiedSixSigmaYellowBeltHandbook to download the online contents.

xv
 Preface

W
elcome to The ASQ Certified Six Sigma Yellow Belt Handbook. This
reference manual is designed to help both those interested in passing
the certification exam of the American Society for Quality (ASQ) for the
Six Sigma Yellow Belt and those who want a handy reference to the appropriate
materials needed for successful Six Sigma projects. I have made a sincere attempt
to make this book a reference for both beginners in Six Sigma and those who are
already knowledgeable about process improvement and variation reduction.
The primary layout of the handbook follows ASQ’s Body of Knowledge (BoK)
for the Certified Six Sigma Yellow Belt (CSSYB) released in 2022. I have used
feedback from Six Sigma practitioners and knowledge gained through helping
others prepare for exams to create a handbook that I hope will be beneficial to
anyone seeking to pass the ASQ CSSYB or other Six Sigma exams. In addition to
the primary text, the handbook contains numerous appendices, a comprehensive
list of abbreviations, and practice exam questions; Online Contents accompanying
the book contain additional materials. A word of caution—you are not allowed to
take any of the exam questions into the ASQ exam. While most ASQ certification
exams use solely a multiple-choice question format (ASQ CMQ/OE and CSSMBB
are exceptions), many users of ASQ handbooks on the academic side prefer essay-
type questions for the chapters to test the comprehension of students using this
book at colleges and universities. I would advise the ASQ exam takers to make a
note of this but not be too concerned. The essay questions are included to challenge
the users. The difficulty level of the essay questions is likely higher than that of
the questions in the ASQ certification exam. Six Sigma trainers for organizations
may find this additional feature useful, as they want their trainees (staff) to not
only pass ASQ Six Sigma exams but have a comprehensive understanding of the
Body of Knowledge that will allow them to support real Six Sigma projects in
their roles.
I am running an ASQ CSSYB handbook users group on LinkedIn and would
greatly appreciate readers’ comments and feedback on how the handbook can
be improved. Constructive and respectful posts are encouraged. Users will be
acknowledged if their input and feedback are found useful and incorporated into
the next edition.
I encourage users of the handbook to read the ASQ Quality Progress publication
“Test Run” to obtain tips for passing the ASQ exam (located in this book’s
Online Contents). Visit asq.org for more information about certification.

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