CLL CLL Visual Management & 5S Methodology 1 — Questions and Answers
Question 1: What is the primary purpose of visual management in a lean workplace?
- To decorate the facility with company branding
- To make the status of operations, standards, and problems immediately visible to anyone (Correct answer)
- To replace all written standard operating procedures
- To track employee attendance and punctuality
Correct answer: To make the status of operations, standards, and problems immediately visible to anyone
Visual management exposes abnormalities instantly so that anyone on the floor can see whether conditions are normal or require action without asking.
Question 2: Which of the five 5S steps focuses on establishing rules and schedules to maintain the first three S conditions?
- Sort (Seiri)
- Set in Order (Seiton)
- Shine (Seiso)
- Standardize (Seiketsu) (Correct answer)
Correct answer: Standardize (Seiketsu)
Standardize creates the norms, checklists, and visual controls that sustain Sort, Set in Order, and Shine activities consistently over time.
Question 3: In 5S, what is the correct action taken with items tagged during the 'Sort' step that are deemed unnecessary?
- Immediately discard all tagged items
- Move tagged items to a red-tag area for evaluation and disposition decision (Correct answer)
- Store them in a locked storage room
- Return them to the supplier
Correct answer: Move tagged items to a red-tag area for evaluation and disposition decision
Red-tag areas hold items pending a structured decision process — kept, relocated, or discarded — preventing arbitrary disposal of potentially useful items.
Question 4: What does an andon system provide in a lean visual management context?
- A method for scheduling employee vacations
- A real-time signal that alerts the team to a production problem requiring immediate response (Correct answer)
- A dashboard for tracking customer order status
- A financial reporting tool for management
Correct answer: A real-time signal that alerts the team to a production problem requiring immediate response
Andon signals — lights, boards, or alerts — notify team leaders and support staff instantly when a worker detects an abnormality, enabling rapid response.
Question 5: Which visual tool defines the acceptable range of a process parameter directly at the point of use?
- Control chart posted in a conference room
- Color-coded gauge with green, yellow, and red zones on the machine (Correct answer)
- Monthly management report
- Bill of materials printout
Correct answer: Color-coded gauge with green, yellow, and red zones on the machine
Color-coded gauges at the point of use let operators instantly see whether a parameter is within spec (green), borderline (yellow), or out of range (red).
Question 6: How does shadow boarding (shadow boards) support the 5S 'Set in Order' step?
- It tracks employee shift assignments on a visible schedule
- It uses silhouette outlines so missing or misplaced tools are immediately obvious (Correct answer)
- It displays key performance indicators on the shop floor
- It identifies inventory storage locations by SKU number
Correct answer: It uses silhouette outlines so missing or misplaced tools are immediately obvious
Shadow boards show the exact shape and location for each tool; an empty shadow signals immediately that a tool is missing or not returned.
CLL CLL Visual Management & 5S Methodology 1
What is the primary purpose of visual management in a lean workplace?