Lean Six Sigma Yellow Belt Certification The Improve Phase 3 — Questions and Answers
Question 1: A team wants to implement mistake-proofing on an assembly line. What Lean term describes this approach?
- Kanban
- Poka-yoke (Correct answer)
- Heijunka
- Jidoka
Correct answer: Poka-yoke
Poka-yoke refers to mistake-proofing devices or methods that prevent errors or make defects immediately detectable.
Question 2: During solution implementation, which stakeholder communication approach is most effective for reducing resistance?
- Sending email announcements after implementation is complete
- Involving key stakeholders early and updating them throughout the process (Correct answer)
- Having only the project sponsor communicate changes
- Limiting communication until all details are finalized
Correct answer: Involving key stakeholders early and updating them throughout the process
Engaging stakeholders early and maintaining ongoing communication builds trust and reduces resistance to change.
Question 3: A Yellow Belt team proposes increasing inventory buffers to prevent stockouts. A lean practitioner would likely challenge this because:
- Inventory is always the most expensive waste
- Excess inventory is considered a waste that hides other process problems (Correct answer)
- Inventory calculations require Black Belt expertise
- Buffer stock violates ISO standards
Correct answer: Excess inventory is considered a waste that hides other process problems
Lean views excess inventory as waste (muda) because it consumes space and capital while masking underlying process instability.
Question 4: What does a 'future state' value stream map represent in the Improve phase?
- How the process currently operates with all its waste
- The ideal process design after waste is eliminated (Correct answer)
- A control chart of future production volumes
- The project timeline for implementation
Correct answer: The ideal process design after waste is eliminated
The future state map depicts the redesigned process with waste removed, serving as the implementation target.
Question 5: A team runs an A/B test comparing two process configurations. After the test, the new configuration shows a statistically significant improvement. What should be the next step?
- Archive the results and close the project
- Develop an implementation plan to roll out the improved configuration (Correct answer)
- Return to the Analyze phase for further root cause analysis
- Present findings to the MBB for approval
Correct answer: Develop an implementation plan to roll out the improved configuration
Once a solution is validated with statistical significance, the team should plan and execute full-scale implementation.
Question 6: Which of the following best describes a 'pull system' in Lean production?
- Production is scheduled based on forecasted demand
- Downstream processes signal upstream processes to produce only what is needed (Correct answer)
- Managers push work orders to all stations simultaneously
- Products are pulled from finished goods inventory as orders arrive
Correct answer: Downstream processes signal upstream processes to produce only what is needed
A pull system uses downstream demand signals (like kanban cards) to trigger upstream production, reducing overproduction.
Question 7: When implementing a solution, what is the primary reason for documenting the new standard operating procedure (SOP)?
- To satisfy auditors during ISO certification reviews
- To ensure the improvement is consistently applied and gains are sustained (Correct answer)
- To justify the cost of the Six Sigma project to management
- To train replacement workers only when turnover occurs
Correct answer: To ensure the improvement is consistently applied and gains are sustained
SOPs capture the improved method so every operator performs the process the same way, sustaining the gains over time.
Lean Six Sigma Yellow Belt Certification The Improve Phase 3
A team wants to implement mistake-proofing on an assembly line.
What Lean term describes this approach?