Mixed Deck — All CLL Topics Flashcards

When a lean project team uses 'reliable promising,' what behavior is being encouraged?

Answer: Making only commitments that can be kept, and proactively communicating when a commitment is at risk

Reliable promising means team members only commit to what they are confident they can deliver and immediately flag threats to those commitments.

Which statistical measure is most useful for identifying the spread of process data around its mean?

Answer: Standard deviation

Standard deviation quantifies how much individual data points deviate from the mean, making it the primary measure of process spread.

After completing a kaizen event, which document should be updated to reflect the improved process and new risk controls?

Answer: The control plan and standardized work documents

Updated control plans and standardized work documents capture the improved state and define ongoing controls to prevent reversion to old risks.

Under Sarbanes-Oxley (SOX) Section 404, what are public companies required to do?

Answer: Assess and report on the effectiveness of internal controls over financial reporting

SOX Section 404 requires management and external auditors to report on the adequacy of internal controls over financial reporting each fiscal year.

A Lean Leader's improvement proposal is rejected by the finance department due to unclear ROI communication. What should the leader do first?

Answer: Reframe the proposal using financial metrics aligned with finance's priorities

Translating Lean improvements into financial language (cost savings, throughput, working capital) increases stakeholder alignment.

When a Lean Leader shares proprietary process improvement methods learned at a previous employer, this raises concerns about:

Answer: Intellectual property and confidentiality obligations

Professionals have ongoing confidentiality obligations to former employers regarding proprietary methods, tools, and trade secrets.

What is the goal of continuous improvement?

Answer: Enhance processes over time

The goal of continuous improvement, often embodied by Kaizen in Lean, is to systematically and incrementally enhance processes, products, and services over an extended period. It involves an ongoing effort to identify and eliminate waste, improve quality, and increase efficiency. This philosophy fosters a culture where everyone is constantly looking for ways to make things better, leading to sustained organizational growth and competitiveness.

During a Lean transformation, a control plan is best described as:

Answer: A document specifying what to monitor, how, and how often to sustain process controls

A control plan details the monitoring methods, frequency, and responsible parties needed to sustain process improvements and prevent recurrence of risks.

In a lean value stream, 'dock-to-dock time' is a measure of what?

Answer: Total time from receiving raw material to shipping finished goods

Dock-to-dock time captures end-to-end throughput time across the entire value stream, revealing total lead time including all wait and process time.

A quality circle is best described as:

Answer: A small group of employees who meet regularly to identify and solve work-related problems

Quality circles are voluntary groups of workers who regularly meet to identify, analyze, and solve quality and productivity problems in their area.

Which of the following best describes 'Cost of Poor Quality' (COPQ)?

Answer: Total cost of internal failures, external failures, appraisal, and prevention activities

COPQ encompasses all costs resulting from producing defects — internal failures, external failures, appraisal, and prevention — quantifying the full impact of poor quality.

What is a compliance audit in CLL practice?

Answer: A systematic review to verify adherence to regulatory requirements and organizational policies

A compliance audit systematically examines an organization's adherence to external regulations, internal policies, and industry standards, identifying gaps and recommending corrective actions to achieve full compliance.

How does milk-run logistics support lean supply chain operations?

Answer: It makes frequent, small-lot pickups from multiple suppliers on a fixed route

Milk-run routes pick up small, frequent quantities from several suppliers, synchronizing inbound flow with production pull and reducing inventory.

A lean leader sees that defect rates are falling but customer complaints are rising. What is the most likely explanation?

Answer: The defect metric is measuring the wrong quality attribute customers care about

A disconnect between internal defect metrics and customer complaints signals that the metric is not capturing what matters to customers (Voice of the Customer).

A factory floor has large stacks of raw material waiting at each workstation 'just in case' production speeds up. This scenario most directly represents which waste?

Answer: Inventory

Excess raw material, WIP, or finished goods held beyond immediate need is the waste of Inventory.

Which risk response strategy involves shifting the negative impact of a risk to a third party?

Answer: Risk transfer

Risk transfer moves the financial or operational burden of a risk to another party, such as through insurance or outsourcing.

In CLL practice, what is the purpose of a standard operating procedure (SOP)?

Answer: To document step-by-step instructions for routine tasks to ensure consistency and quality

SOPs provide standardized, detailed instructions for routine operations, ensuring consistency, quality, efficiency, and safety regardless of which qualified individual performs the task.

A Kaizen event (also called a Kaizen blitz) is typically how long in duration?

Answer: 1–5 days

Kaizen events are short, focused improvement activities usually lasting 3 to 5 days to rapidly address a specific process problem.

In CLL practice, what is the purpose of a standard operating procedure (SOP)?

Answer: To document step-by-step instructions for routine tasks to ensure consistency and quality

SOPs provide standardized, detailed instructions for routine operations, ensuring consistency, quality, efficiency, and safety regardless of which qualified individual performs the task.

What role does a Kaizen facilitator primarily serve during an improvement event?

Answer: Guide the team through the structured process while keeping them focused on the goal

The facilitator keeps the team on track, manages time, resolves conflicts, and ensures the structured improvement methodology is followed.