Lean Six Sigma Yellow Belt Certification Control and Sustainment Methods 5 — Questions and Answers
Question 1: What is the main purpose of a 'transition plan' at the end of a Lean Six Sigma project?
- To document lessons learned for the project portfolio
- To hand off ownership of the improved process and controls to the process owner (Correct answer)
- To identify the next improvement project
- To calculate final project savings
Correct answer: To hand off ownership of the improved process and controls to the process owner
A transition plan formally transfers responsibility for sustaining the gains from the project team to the day-to-day process owner.
Question 2: Why is it important to establish a 'benefit realization review' several months after project closure?
- To assign blame if results deteriorate
- To verify that the expected financial and quality improvements are being sustained over time (Correct answer)
- To start a new DMAIC cycle immediately
- To update the project charter
Correct answer: To verify that the expected financial and quality improvements are being sustained over time
A post-project review confirms that gains held after the project team disengaged and helps identify if corrective action is needed.
Question 3: Which of the following best describes 'management review' as a sustainment tool?
- Managers personally fixing every process deviation
- Periodic structured reviews of key metrics to confirm the process remains in control (Correct answer)
- Removing control charts once targets are met
- Restarting DMAIC from the Define phase
Correct answer: Periodic structured reviews of key metrics to confirm the process remains in control
Management reviews provide oversight by regularly examining KPIs and control chart data to ensure improvements are maintained.
Question 4: A process that was improved 6 months ago is showing gradual performance degradation. This most likely indicates:
- The improvement was incorrectly scoped
- Controls were not adequately maintained or sustained after project closure (Correct answer)
- The measurement system has failed
- The specification limits need to be widened
Correct answer: Controls were not adequately maintained or sustained after project closure
Gradual regression typically results from insufficient sustainment — controls not being enforced, SOPs not followed, or no ongoing monitoring.
Question 5: Which of the following actions best reinforces a culture of sustainment within a team?
- Rotating process ownership every month
- Recognizing and rewarding adherence to new standards and continuous compliance (Correct answer)
- Reducing audit frequency after the first successful audit
- Removing visual controls once operators are trained
Correct answer: Recognizing and rewarding adherence to new standards and continuous compliance
Positive reinforcement of compliant behaviors embeds the new standard into team culture, making sustainment self-reinforcing.
Question 6: In the context of Control and Sustainment, what does 'process discipline' mean?
- Punishing operators who deviate from the process
- Consistently following the defined process steps every time, regardless of pressure to shortcut (Correct answer)
- Reducing process steps to increase speed
- Applying SPC only during audits
Correct answer: Consistently following the defined process steps every time, regardless of pressure to shortcut
Process discipline means that the standardized method is always followed as defined, which is the foundation of any sustained improvement.
Question 7: An operator notices that a control chart has been out of control for three consecutive shifts but no action has been taken. Which sustainment element has broken down?
- The SIPOC diagram
- The response plan and escalation process within the control plan (Correct answer)
- The project charter
- The measurement system analysis
Correct answer: The response plan and escalation process within the control plan
A control plan's response plan defines who must act and how quickly when out-of-control signals occur; inaction means the response plan is not being followed.
Lean Six Sigma Yellow Belt Certification Control and Sustainment Methods 5
What is the main purpose of a 'transition plan' at the end of a Lean Six Sigma project?