Certified Six Sigma Black Belt Lean Enterprise Concepts Questions and Answers

Question 1

A team is analyzing a process that has long and unpredictable changeover times between product models, leading to excessive downtime and large batch sizes. Which of the following Lean tools is specifically designed to address this type of problem?

Accepted Answer

Single-Minute Exchange of Die (SMED)

Answer

Single-Minute Exchange of Die (SMED) is a system focused on dramatically reducing the time it takes to complete equipment changeovers. Its primary goal is to convert as many changeover steps as possible to 'external' (performed while the equipment is running) and to streamline the remaining 'internal' steps. This reduction in changeover time allows for smaller batch sizes, increased flexibility, and less downtime.

Question 2

A customer contact center operates for an 8-hour shift (480 minutes). During this shift, there is one 30-minute lunch and two 15-minute breaks. The daily customer demand is 210 calls. What is the Takt Time for this process?

Accepted Answer

2.00 minutes per call

Answer

Takt Time is calculated as Net Available Work Time divided by Customer Demand. First, calculate the Net Available Work Time: 480 minutes - 30 minutes (lunch) - 2 * 15 minutes (breaks) = 420 minutes. Then, divide by the customer demand: 420 minutes / 210 calls = 2.00 minutes per call. This means a call must be completed every 2 minutes to keep pace with customer demand.

Question 3

Which of the following BEST describes the primary purpose of Heijunka (production leveling)?

Accepted Answer

To smooth the production of different product models over time to match the pace of customer demand.

Answer

Heijunka, or production leveling, is a technique used to reduce unevenness (Mura) in the production process. Its primary goal is to produce goods at a constant rate, leveling the mix and volume of products over time to dampen the fluctuations of customer orders and create a more predictable and stable workflow.

Question 4

A manager notices that experienced machine operators are frequently assigned simple, repetitive tasks far below their skill level, while complex problem-solving is escalated to engineers who are often unavailable. This practice leads to delays and low morale among the operators. According to the 8 Wastes of Lean, which waste is most evident in this scenario?

Accepted Answer

Non-Utilized Talent

Answer

This scenario is a classic example of Non-Utilized Talent (or underutilized skills), which is recognized as the 8th waste of Lean. It occurs when an organization fails to use the full knowledge, creativity, and skills of its workforce. Assigning highly skilled operators to menial tasks instead of empowering them to solve problems is a waste of human potential.

Question 5

The Lean principle of Jidoka, often translated as 'autonomation', is best described as:

Accepted Answer

Providing machines and operators the ability to detect an abnormal condition and immediately stop work.

Answer

Jidoka, or 'autonomation' (automation with a human touch), is a core pillar of the Toyota Production System. It empowers either the machine or the operator to halt the production process as soon as an abnormality or defect is detected. This prevents the production of further defects and allows for immediate investigation into the root cause of the problem.

Certified Six Sigma Black Belt Exam Practice Test

Certified Six Sigma Black Belt Exam Practice Test

Certified Six Sigma Black Belt Lean Enterprise Concepts Questions and Answers