Free Lean Six Sigma Yellow Belt Control and Sustainment Methods Questions and Answers

Question 1

A team has successfully implemented a new process to reduce defects. To ensure the improvements are maintained long-term, they create a document that specifies the critical metrics to monitor, the measurement frequency, and a clear reaction plan for when the process goes out of control. What is this document called?

Accepted Answer

Control Plan

Answer

A Control Plan is a key deliverable of the Control phase. It is a living document that provides a written summary of the methods needed to keep a process at its improved level, including what to monitor, how to monitor it, and what to do if performance degrades.

Question 2

In a manufacturing facility, a new assembly fixture is designed so that a component can only be inserted in the correct orientation. It is now physically impossible for the operator to install the part backward. This is a classic example of which Lean technique?

Accepted Answer

Poka-Yoke

Answer

Poka-Yoke is a Japanese term for 'mistake-proofing'. It refers to any mechanism in a process that helps prevent mistakes from happening or makes them immediately obvious. Designing the fixture to prevent incorrect assembly is a perfect example of this principle.

Question 3

Which of the following is the PRIMARY purpose of creating and maintaining Standard Operating Procedures (SOPs) as a sustainment method?

Accepted Answer

To ensure tasks are performed consistently and to a set quality standard.

Answer

Standard Operating Procedures (SOPs) are detailed, step-by-step instructions designed to ensure that routine tasks are performed consistently and correctly every time. This standardization is a critical method for sustaining the gains achieved in an improvement project.

Question 4

A project team has completed all phases of their DMAIC project, implemented the improvements, and monitored the results. What is the final step they must take to officially conclude the project and hand over the new process to the process owner?

Accepted Answer

Conduct a formal Project Closure.

Answer

Project Closure is the formal final step where the team documents the results and lessons learned, gets sign-off from stakeholders, and officially transfers ownership of the sustained process to the process owner. This ensures the improvements are integrated into normal business operations.

Question 5

After implementing a process change, a team uses a control chart to monitor a key performance indicator. They notice that all the data points are within the upper and lower control limits and show a random pattern around the centerline. What does this indicate about the process?

Accepted Answer

The process is stable and exhibiting only common cause variation.

Answer

A process is considered 'in control' or stable when the data points on a control chart fall between the control limits in a random pattern. This indicates that the variation present is inherent to the process (common cause) and is predictable.

Lean Six Sigma Yellow Belt Certification Practice Test

Lean Six Sigma Yellow Belt Certification Practice Test

Free Lean Six Sigma Yellow Belt Control and Sustainment Methods Questions and Answers