Lean Six Sigma Yellow Belt Certification The Control Phase 4 — Questions and Answers
Question 1: What is the purpose of a 'handoff' or transition plan at the end of a DMAIC project?
- To transfer project documentation to the finance department for cost tracking
- To ensure the process owner and operators can sustain the improvements without the project team (Correct answer)
- To formally close the project charter and release team members
- To schedule a follow-up DMAIC project on the same process
Correct answer: To ensure the process owner and operators can sustain the improvements without the project team
A handoff plan ensures the process owner has the knowledge, tools, and authority to maintain improvements after the project team disbands.
Question 2: Which type of control is generally considered the most robust for preventing defects?
- Training and retraining employees
- Visual reminders and warning signs
- Engineering or physical controls (mistake-proofing) (Correct answer)
- Periodic audits and management reviews
Correct answer: Engineering or physical controls (mistake-proofing)
Engineering controls are the most robust because they prevent errors automatically without relying on human memory or compliance.
Question 3: In the Control phase, a 'replication plan' refers to:
- Duplicating the measurement system to check for gauge error
- Applying successful improvements to similar processes or locations across the organization (Correct answer)
- Repeating the Analyze phase to validate root causes
- Creating backup control charts in case the primary is lost
Correct answer: Applying successful improvements to similar processes or locations across the organization
A replication plan identifies other areas of the business where the same improvements can be implemented to multiply the benefit.
Question 4: What does 'Sustain' (the 5th S in 5S) require from leadership?
- A one-time audit to certify the workspace is organized
- Ongoing reinforcement, audits, and accountability to maintain standards (Correct answer)
- Purchasing new storage equipment and labeling systems
- Delegating all 5S activities entirely to front-line employees
Correct answer: Ongoing reinforcement, audits, and accountability to maintain standards
Sustain requires consistent leadership reinforcement through regular audits, recognition, and accountability to prevent backsliding.
Question 5: When should control chart control limits be recalculated?
- Every month on a fixed schedule
- Whenever a data point falls outside the limits
- After a confirmed process change has been implemented and stabilized (Correct answer)
- When the data no longer follows a normal distribution
Correct answer: After a confirmed process change has been implemented and stabilized
Control limits should be recalculated only after a deliberate, confirmed process change so the chart reflects the new baseline performance.
Question 6: A Yellow Belt project team has completed improvements and verified results. Which document most directly supports ongoing process stability monitoring?
- Project charter
- SIPOC diagram
- Control chart with response plan (Correct answer)
- Cause-and-effect matrix
Correct answer: Control chart with response plan
A control chart paired with a response plan provides real-time monitoring and pre-defined actions to maintain process stability.
Question 7: What is a 'lessons learned' document in the context of the Control phase?
- A list of all the defects found during the Measure phase
- A record capturing what worked, what didn't, and recommendations for future projects (Correct answer)
- A final report submitted to the customer confirming defect reduction
- A detailed statistical analysis of control chart patterns
Correct answer: A record capturing what worked, what didn't, and recommendations for future projects
A lessons learned document captures insights from the project so future teams can benefit from the experience and avoid repeating mistakes.
Lean Six Sigma Yellow Belt Certification The Control Phase 4
What is the purpose of a 'handoff' or transition plan at the end of a DMAIC project?