Control and Sustainment Methods Flashcards
7 cards from real Lean Six Sigma Yellow Belt Certification practice questions. Tap to flip, then mark Knew It or Still Learning — missed cards come back until you master them.
Read the first 7 Control and Sustainment Methods flashcards as text
Why are Standard Operating Procedures (SOPs) critical to sustaining process improvements?
Answer: They capture the best-known method and ensure consistency across operators and shifts
SOPs document the improved process steps so all operators perform the work consistently, preventing regression to old habits.
Which element is most important to include in a Standard Operating Procedure for sustainment?
Answer: Step-by-step instructions with expected outcomes and quality checkpoints
Effective SOPs include clear step-by-step instructions and quality checkpoints so operators know both what to do and what a good outcome looks like.
A 5S audit is conducted during the Control phase primarily to:
Answer: Verify that workplace organization standards are being maintained
5S audits in the Control phase confirm that Sort, Set in Order, Shine, Standardize, and Sustain practices are being upheld over time.
What is the main risk of failing to update SOPs after a process improvement?
Answer: Operators revert to old methods, eroding the gains
Without updated SOPs, operators may default to pre-improvement habits, causing the process to regress and wasting the improvement effort.
Which training approach best ensures operators can sustain a new process standard?
Answer: Hands-on training with return demonstration and competency verification
Return demonstration lets the trainer verify the operator can correctly perform the new method before working independently.
Which document links each process step to its key control variables, measurement method, and responsible owner?
Answer: Control Plan
A Control Plan maps each critical process step to what is measured, how it is measured, frequency, and who is accountable.
During a process audit in the Control phase, an auditor finds operators are skipping a step defined in the SOP. The BEST immediate action is to:
Answer: Retrain operators and investigate why the step is being skipped
Retraining corrects the behavior while investigating the root cause determines whether the SOP step needs adjustment or reinforcement.