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
Poka-yoke devices are used in the Control phase primarily to:
Answer: Prevent defects by making errors physically impossible or immediately detectable
Poka-yoke (mistake-proofing) designs the process or tooling so errors either cannot occur or are caught immediately before becoming defects.
Visual management tools, such as shadow boards and floor markings, support sustainment by:
Answer: Making the standard condition instantly visible so deviations are obvious
Visual management makes the correct state of the workplace or process immediately apparent so anyone can see at a glance when something is out of place.
A warning poka-yoke differs from a control poka-yoke in that it:
Answer: Alerts the operator to an error but does not stop the process automatically
A warning poka-yoke (e.g., an alarm or light) signals that an error has occurred, while a control poka-yoke physically prevents the error.
Which of the following is the strongest form of mistake-proofing?
Answer: Physical design that makes incorrect assembly mechanically impossible
Physical design changes (e.g., asymmetric connectors) are the strongest poka-yoke because they eliminate the possibility of error regardless of operator attention.
A visual control is effective in sustainment when it:
Answer: Communicates process status to anyone who looks, without explanation
Effective visual controls are self-explaining — anyone walking past the area should immediately understand whether the process is normal or abnormal.
An andon light system in a manufacturing cell is an example of which sustaining tool?
Answer: Visual management / visual control
An andon is a visual (and sometimes audible) signal that displays process status and alerts operators and team leads to abnormal conditions.
Which scenario best illustrates a successful poka-yoke implementation?
Answer: A connector designed so it can only be inserted in the correct orientation
A connector that physically can only go in one way prevents mis-assembly without requiring operator attention, making it a true mistake-proof design.