CLL CLL Visual Management & 5S Methodology 2 — Questions and Answers
Question 1: What is the fifth and final S in the 5S methodology, and what does it require of the lean leader?
- Safety — adding safety signage throughout the facility
- Sustain (Shitsuke) — building discipline and habits so improvements become the new standard (Correct answer)
- Systemize — digitizing all 5S records
- Summarize — reporting 5S scores to upper management
Correct answer: Sustain (Shitsuke) — building discipline and habits so improvements become the new standard
Sustain requires leadership reinforcement, regular audits, and a culture of accountability to prevent backsliding into old habits.
Question 2: Which type of visual control physically prevents a defect or error from occurring rather than simply signaling a problem?
- Andon light
- Poka-yoke (mistake-proofing) device (Correct answer)
- Kanban card
- 5S audit checklist
Correct answer: Poka-yoke (mistake-proofing) device
A poka-yoke device makes it physically impossible or immediately self-evident to commit an error, achieving zero-defect quality at the source.
Question 3: In a lean facility, what is the purpose of floor markings and painted lanes?
- Aesthetic improvement and OSHA compliance only
- To define standard locations for material, equipment, and pedestrian paths so deviations are instantly visible (Correct answer)
- To guide forklift drivers on new routes only
- To comply with fire marshal inspection requirements
Correct answer: To define standard locations for material, equipment, and pedestrian paths so deviations are instantly visible
Floor markings establish visual standards for where everything belongs so any out-of-place item or deviation from the standard is self-evident.
Question 4: What is a 5S audit, and how frequently should it typically be conducted in a lean environment?
- An annual safety inspection conducted by external auditors
- A structured, scored workplace assessment conducted regularly (often weekly or monthly) to verify and sustain 5S standards (Correct answer)
- A one-time baseline assessment before implementing lean
- A financial audit of 5S program spending
Correct answer: A structured, scored workplace assessment conducted regularly (often weekly or monthly) to verify and sustain 5S standards
Regular scored audits create accountability, identify backsliding early, and reinforce leadership commitment to maintaining standards.
Question 5: How does visual management support the lean concept of 'management by exception'?
- It requires managers to review all data daily regardless of status
- It highlights only abnormal conditions so leaders can focus attention where problems exist (Correct answer)
- It eliminates the need for daily team meetings
- It automates decision-making without human input
Correct answer: It highlights only abnormal conditions so leaders can focus attention where problems exist
Visual systems surface abnormalities automatically, allowing managers to focus intervention only where standards are not being met.
Question 6: Which lean concept uses a visible board — often a physical or digital card system — to signal that work can move to the next process step?
- SIPOC diagram
- Kanban pull signal (Correct answer)
- Fishbone diagram
- A3 report
Correct answer: Kanban pull signal
Kanban cards or signals authorize movement of material or work only when downstream capacity exists, enforcing pull and making flow visible.
CLL CLL Visual Management & 5S Methodology 2
What is the fifth and final S in the 5S methodology, and what does it require of the lean leader?