Free Lean Six Sigma Yellow Belt Control and Sustainment Methods Questions and Answers — Questions and Answers
Question 1: A team has successfully implemented a new process to reduce defects. To ensure the improvements are maintained long-term, they create a document that specifies the critical metrics to monitor, the measurement frequency, and a clear reaction plan for when the process goes out of control. What is this document called?
- Project Charter
- Control Plan (Correct answer)
- Fishbone Diagram
- Gantt Chart
Correct answer: Control Plan
A Control Plan is a key deliverable of the Control phase. It is a living document that provides a written summary of the methods needed to keep a process at its improved level, including what to monitor, how to monitor it, and what to do if performance degrades.
Question 2: In a manufacturing facility, a new assembly fixture is designed so that a component can only be inserted in the correct orientation. It is now physically impossible for the operator to install the part backward. This is a classic example of which Lean technique?
- Kaizen
- Kanban
- Poka-Yoke (Correct answer)
- 5S
Correct answer: Poka-Yoke
Poka-Yoke is a Japanese term for 'mistake-proofing'. It refers to any mechanism in a process that helps prevent mistakes from happening or makes them immediately obvious. Designing the fixture to prevent incorrect assembly is a perfect example of this principle.
Question 3: Which of the following is the PRIMARY purpose of creating and maintaining Standard Operating Procedures (SOPs) as a sustainment method?
- To identify the root causes of defects in a process.
- To ensure tasks are performed consistently and to a set quality standard. (Correct answer)
- To track the timeline and budget of an improvement project.
- To brainstorm potential solutions during the Improve phase.
Correct answer: To ensure tasks are performed consistently and to a set quality standard.
Standard Operating Procedures (SOPs) are detailed, step-by-step instructions designed to ensure that routine tasks are performed consistently and correctly every time. This standardization is a critical method for sustaining the gains achieved in an improvement project.
Question 4: A project team has completed all phases of their DMAIC project, implemented the improvements, and monitored the results. What is the final step they must take to officially conclude the project and hand over the new process to the process owner?
- Perform a final Root Cause Analysis.
- Update the Project Charter with the results.
- Conduct a formal Project Closure. (Correct answer)
- Create a new Value Stream Map.
Correct answer: Conduct a formal Project Closure.
Project Closure is the formal final step where the team documents the results and lessons learned, gets sign-off from stakeholders, and officially transfers ownership of the sustained process to the process owner. This ensures the improvements are integrated into normal business operations.
Question 5: After implementing a process change, a team uses a control chart to monitor a key performance indicator. They notice that all the data points are within the upper and lower control limits and show a random pattern around the centerline. What does this indicate about the process?
- The process is out of control and requires immediate intervention.
- The process is stable and exhibiting only common cause variation. (Correct answer)
- A special cause variation has been introduced into the process.
- The control limits need to be recalculated immediately.
Correct answer: The process is stable and exhibiting only common cause variation.
A process is considered 'in control' or stable when the data points on a control chart fall between the control limits in a random pattern. This indicates that the variation present is inherent to the process (common cause) and is predictable.
Question 6: Which of the following activities is NOT typically part of the Control phase of a DMAIC project?
- Developing a detailed Root Cause Analysis using a Fishbone Diagram. (Correct answer)
- Creating a plan to monitor the ongoing performance of the process.
- Documenting the new process with Standard Operating Procedures (SOPs).
- Transferring ownership of the improved process to the process owner.
Correct answer: Developing a detailed Root Cause Analysis using a Fishbone Diagram.
Developing a detailed Root Cause Analysis, such as using a Fishbone Diagram, is a primary activity of the Analyze phase, not the Control phase. The Control phase focuses on sustaining the improvements that were developed based on the findings from the Analyze phase.
Free Lean Six Sigma Yellow Belt Control and Sustainment Methods Questions and Answers
A team has successfully implemented a new process to reduce defects.
To ensure the improvements are maintained long-term, they create a document that specifies the critical metrics to monitor, the measurement frequency, and a clear reaction plan for when the process goes out of control.
What is this document called?