CLL CLL Visual Management & 5S Methodology 2

Question 1

What is the fifth and final S in the 5S methodology, and what does it require of the lean leader?

Accepted Answer

Sustain (Shitsuke) — building discipline and habits so improvements become the new standard

Answer

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?

Accepted Answer

Poka-yoke (mistake-proofing) device

Answer

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?

Accepted Answer

To define standard locations for material, equipment, and pedestrian paths so deviations are instantly visible

Answer

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?

Accepted Answer

A structured, scored workplace assessment conducted regularly (often weekly or monthly) to verify and sustain 5S standards

Answer

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'?

Accepted Answer

It highlights only abnormal conditions so leaders can focus attention where problems exist

Answer

Visual systems surface abnormalities automatically, allowing managers to focus intervention only where standards are not being met.

(CLL) Certified Lean Leader Practice Test