Control Phase Test YB.

1. Question

Which principle of the 5S methodology is about avoiding falling back to the old ways of cluttered and unorganized work environment?

Sorting

Correct Incorrect Correct answer

Shining

Correct Incorrect Correct answer

Standardizing

Correct Incorrect Correct answer

Sustaining

Correct Incorrect Correct answer

2. Question

A Black Belt stores tools in marked locations so that workers can find and access them easily when they are needed. Which principle of 5S methodology is the Black Belt applying?

Shining

Correct Incorrect Correct answer

Sustaining

Correct Incorrect Correct answer

Sorting

Correct Incorrect Correct answer

Straightening (Set in Order)

Correct Incorrect Correct answer

3. Question

Which of these 5S’s is the first in the order of proper execution?

Shine

Correct Incorrect Correct answer

Set in Order

Correct Incorrect Correct answer

Sort

Correct Incorrect Correct answer

Standardize

Correct Incorrect Correct answer

4. Question

Poka-Yoke eliminates the defect as early as possible in the process

True

Correct Incorrect Correct answer

False

Correct Incorrect Correct answer

5. Question

Kanban system is a ______ driven system?

Pull

Correct Incorrect Correct answer

Push

Correct Incorrect Correct answer

6. Question

5S Sorting: Items used weekly should be kept _______?

Within arm's reach

Correct Incorrect Correct answer

In a local location

Correct Incorrect Correct answer

In a remote location

Correct Incorrect Correct answer

7. Question

Kanban systems are quick fixes to large inventory problems, workforce issues, poor product planning, fluctuating demand cycles etc.

Correct

Correct Incorrect Correct answer

Incorrect

Correct Incorrect Correct answer

8. Question

Mistake proofing is defined as…

Making sure we discover when a defect occurs

Correct Incorrect Correct answer

Using wisdom or ingenuity to create devices allowing 100% defect free steps 100% of the time

Correct Incorrect Correct answer

Find the reason (proof) of mistakes

Correct Incorrect Correct answer

9. Question

Which would not be representative of good mistake proofing?

be as simple as possible

Correct Incorrect Correct answer

require no investment in money or resources

Correct Incorrect Correct answer

be automatic where possible

Correct Incorrect Correct answer

10. Question

The 5S principle that says remove all items not required for the re-occurring work at hand and keeping only essentials nearby is known as?

Sorting

Correct Incorrect Correct answer

Shining

Correct Incorrect Correct answer

Straightening

Correct Incorrect Correct answer

Standardizing

Correct Incorrect Correct answer

11. Question

The Lean technique that focuses on making “important work flow issues” noticeable is called?

Value Stream

Correct Incorrect Correct answer

Muda

Correct Incorrect Correct answer

Visual Factory

Correct Incorrect Correct answer

Kaizen

Correct Incorrect Correct answer

12. Question

A method utilized to streamline workflow in a manner that minimizes waste through the use of signals that trigger “flow” through each process step is known as?

Mistake Proofing

Correct Incorrect Correct answer

Kanban

Correct Incorrect Correct answer

Sustaining

Correct Incorrect Correct answer

Shewhart Principle

Correct Incorrect Correct answer

13. Question

The practice of utilizing Mistake Proofing is also known as…

Detection

Correct Incorrect Correct answer

Lean Controls

Correct Incorrect Correct answer

Inspection

Correct Incorrect Correct answer

Poka-Yoke

Correct Incorrect Correct answer

14. Question

The 5S approach utilized by a Belt to separate necessary from unnecessary items and frequently used items from infrequently used items is known as?

Sorting

Correct Incorrect Correct answer

Shining

Correct Incorrect Correct answer

Standardizing

Correct Incorrect Correct answer

Sustaining

Correct Incorrect Correct answer

15. Question

As part of a 5S activity, tags or stickers are used to identify items in need of elimination or another categorization. This process is conducted at what stage of the 5S process?

Sort

Correct Incorrect Correct answer

Set in Order

Correct Incorrect Correct answer

Shine

Correct Incorrect Correct answer

Standardize

Correct Incorrect Correct answer

16. Question

The use of Kanbans work best with pull systems for determining the timing of which products or services are produced

True

Correct Incorrect Correct answer

False

Correct Incorrect Correct answer

17. Question

When a Belt applies the practice of Poka-Yoke to a project, she/he is attempting to make certain the activity is _______

Mistake proofed

Correct Incorrect Correct answer

Well documented

Correct Incorrect Correct answer

Removed from the line

Correct Incorrect Correct answer

Highly visible

Correct Incorrect Correct answer

18. Question

In 5S, the approach that deals with cleansing, repairing, and/or painting machinery or other work spaces is known as which stage?

Shine

Correct Incorrect Correct answer

Sort

Correct Incorrect Correct answer

Sustain

Correct Incorrect Correct answer

Standardize

Correct Incorrect Correct answer

19. Question

Return on Investment (ROI) is the ratio of net financial benefits (either gain or loss) on a project or investment, to the financial costs?

True

Correct Incorrect Correct answer

False

Correct Incorrect Correct answer

20. Question

Net Present Value (NPV) is total value of all future cash flows discounted to today’s value?

True

Correct Incorrect Correct answer

False

Correct Incorrect Correct answer

21. Question

Which of the following reasons would not be a reason why one financial benefit estimation might differ from another?

Use of different discount rates

Correct Incorrect Correct answer

Different control plans

Correct Incorrect Correct answer

Different assumptions on project duration

Correct Incorrect Correct answer

Different assumption on project costs

Correct Incorrect Correct answer

22. Question

All the following are benefits of control plans except?

Ensures compliance with changes through auditing and corrective actions

Correct Incorrect Correct answer

Standardizes processes and work procedures

Correct Incorrect Correct answer

Helps to analyze and eliminate potential x's

Correct Incorrect Correct answer

Measures process performance, stability and capability

Correct Incorrect Correct answer

23. Question

Which of the following should not be a component of a control plan?

Key Metrics

Correct Incorrect Correct answer

Work Breakdown Structure

Correct Incorrect Correct answer

Specification Limits

Correct Incorrect Correct answer

Mitigation Actions

Correct Incorrect Correct answer

24. Question

Which of the following would not be among the collective elements of a great control plan?

Standard Operating Procedures

Correct Incorrect Correct answer

VOC

Correct Incorrect Correct answer

Training Plans

Correct Incorrect Correct answer

Response Plans

Correct Incorrect Correct answer

25. Question

Standard Operating Procedures should never include process maps or step by step procedures?

True

Correct Incorrect Correct answer

False

Correct Incorrect Correct answer

26. Question

Communication plans are intended to plan and prepare for the dissemination of information?

True

Correct Incorrect Correct answer

False

Correct Incorrect Correct answer

27. Question

Communication plans should always include the intended audience, message and purpose?

True

Correct Incorrect Correct answer

False

Correct Incorrect Correct answer

28. Question

Standard Operating Procedures should never be documented?

True

Correct Incorrect Correct answer

False

Correct Incorrect Correct answer

29. Question

Control charts present the voice of the ______?

Process

Correct Incorrect Correct answer

Customer

Correct Incorrect Correct answer

Business

Correct Incorrect Correct answer

Associate

Correct Incorrect Correct answer

30. Question

The first test in the Western Electric Rules is to check whether any one point on the control chart is more than ______ standard deviations away from the center line?

3

Correct Incorrect Correct answer

1

Correct Incorrect Correct answer

6

Correct Incorrect Correct answer

31. Question

A Control Plan is finalized at the end of a LEAN Six Sigma project and given to the Process Owner so she/he can follow it exactly for the remaining life of the process

True

Correct Incorrect Correct answer

False

Correct Incorrect Correct answer

32. Question

As part of the deliverables from a Belt in the control phase of a LSS project, guidelines must be established as to what process operators are to do when outputs begin to operate outside of established limits. These guidelines are known as the _________.

Specification Limits

Correct Incorrect Correct answer

Kanban System

Correct Incorrect Correct answer

Control Limits

Correct Incorrect Correct answer

Response Plan

Correct Incorrect Correct answer

33. Question

The Control Plan is created following the finalization of the Improve phase and can be closed when?

After the project costs have been recouped

Correct Incorrect Correct answer

When the Sponsor says so

Correct Incorrect Correct answer

Never, a control plan must stay in place

Correct Incorrect Correct answer

End of year (project year)

Correct Incorrect Correct answer

34. Question

The use of station warning lights, tools boards, and jidoka devices represent the use of which lean concept?

Visual Factory

Correct Incorrect Correct answer

Gemba

Correct Incorrect Correct answer

Muda

Correct Incorrect Correct answer

35. Question

A concept that addresses the consistency of process-workers is called ________?

Visual Factory

Correct Incorrect Correct answer

Supervising

Correct Incorrect Correct answer

Standard Operating Procedures

Correct Incorrect Correct answer

36. Question

When it comes to Control, one of the most effective means of eliminating defects is to…

Keep a Six Sigma project going on the process at all times

Correct Incorrect Correct answer

Design defect prevention into the product or process

Correct Incorrect Correct answer

Train personnel often and thoroughly

Correct Incorrect Correct answer

Have each process consist of no more than five steps

Correct Incorrect Correct answer

37. Question

A Belt concludes a Lean Six Sigma project with the creation of a Control Plan. At what point should the Control Plan be closed out?

Never, a Control Plan is a living document

Correct Incorrect Correct answer

When the project is delivered to the process owner

Correct Incorrect Correct answer

When the process is in control

Correct Incorrect Correct answer

When the process has been in control for 12 months

Correct Incorrect Correct answer

38. Question

If a project yields monthly savings of $4,000 beginning 4 months after implementation with an initial investment of $42,000 and training costs of $2,000, what is the 3-year ROI from implementation?

1.9

Correct Incorrect Correct answer

2.9

Correct Incorrect Correct answer

2.27

Correct Incorrect Correct answer

3.27

Correct Incorrect Correct answer

39. Question

If a project yields monthly savings of $4,000 beginning 4 months after implementation with an initial investment of $42,000 and training costs of $2,000, what is the 5-year ROI from implementation?

4.09

Correct Incorrect Correct answer

4.45

Correct Incorrect Correct answer

5.09

Correct Incorrect Correct answer

5.45

Correct Incorrect Correct answer

40. Question

What is the main objective of implementing 5S in a process?

To create a clean, organized, and efficient work environment

Correct Incorrect Correct answer

To reduce cost only

Correct Incorrect Correct answer

To standardize SPC charts

Correct Incorrect Correct answer

To automate inspection

Correct Incorrect Correct answer

41. Question

What do the five S’s in 5S stand for?

Sort, Set in order, Shine, Standardize, Sustain

Correct Incorrect Correct answer

Sort, Save, Shine, Schedule, Standardize

Correct Incorrect Correct answer

Simplify, Sort, Standardize, Sustain, Solve

Correct Incorrect Correct answer

Select, Simplify, Support, Shine, Standardize

Correct Incorrect Correct answer

42. Question

Which of the following is a direct benefit of 5S implementation?

Increased lead time

Correct Incorrect Correct answer

Improved visibility and detection of abnormalities

Correct Incorrect Correct answer

Higher complexity

Correct Incorrect Correct answer

Reduced operator accountability

Correct Incorrect Correct answer

43. Question

What is the primary purpose of a Kanban system?

To automate process control

Correct Incorrect Correct answer

To signal replenishment and control inventory levels

Correct Incorrect Correct answer

To record downtime

Correct Incorrect Correct answer

To track customer complaints

Correct Incorrect Correct answer

44. Question

Kanban is most closely aligned with which Lean principle?

Pull production

Correct Incorrect Correct answer

Push production

Correct Incorrect Correct answer

Batch processing

Correct Incorrect Correct answer

Continuous inspection

Correct Incorrect Correct answer

45. Question

What is the definition of “Poka-Yoke”?

A mistake-proofing device or method that prevents errors from occurring

Correct Incorrect Correct answer

A Lean scheduling tool

Correct Incorrect Correct answer

A preventive maintenance plan

Correct Incorrect Correct answer

A standard operating procedure

Correct Incorrect Correct answer

46. Question

Which of the following is an example of a Poka-Yoke device?

A USB plug that fits only one way

Correct Incorrect Correct answer

A work instruction checklist

Correct Incorrect Correct answer

A Kanban signal

Correct Incorrect Correct answer

A job rotation plan

Correct Incorrect Correct answer

47. Question

What is the primary function of visual management in Lean?

To make process status, performance, and abnormalities immediately visible

Correct Incorrect Correct answer

To reduce energy use

Correct Incorrect Correct answer

To store documents

Correct Incorrect Correct answer

To limit variation

Correct Incorrect Correct answer

48. Question

Why is Standard Work important in Lean control?

It limits innovation

Correct Incorrect Correct answer

It ensures consistent performance and forms the baseline for improvement

Correct Incorrect Correct answer

It eliminates all variation

Correct Incorrect Correct answer

It reduces training cost only

Correct Incorrect Correct answer

49. Question

What is the biggest challenge with sustaining 5S?

Lack of storage space

Correct Incorrect Correct answer

Maintaining discipline and consistent follow-up audits

Correct Incorrect Correct answer

Excess tools

Correct Incorrect Correct answer

Training documentation

Correct Incorrect Correct answer

50. Question

A “visual factory” is best described as what?

A facility that uses video monitoring for safety

Correct Incorrect Correct answer

A workplace where process performance, status, and problems are visible to everyone

Correct Incorrect Correct answer

A Lean simulation lab

Correct Incorrect Correct answer

A centralized control room

Correct Incorrect Correct answer

51. Question

What is the main purpose of an Andon system?

To monitor machine temperature

Correct Incorrect Correct answer

To alert teams immediately when a process abnormality occurs

Correct Incorrect Correct answer

To control Kanban cards

Correct Incorrect Correct answer

To reduce lead time

Correct Incorrect Correct answer

52. Question

What distinguishes error prevention from error detection?

Prevention stops errors before they happen; detection identifies them afterward

Correct Incorrect Correct answer

Detection is proactive

Correct Incorrect Correct answer

Prevention requires audits

Correct Incorrect Correct answer

Detection eliminates root causes

Correct Incorrect Correct answer

53. Question

A sensor that stops a machine when a part is missing is an example of which Poka-Yoke category?

Prevention

Correct Incorrect Correct answer

Detection

Correct Incorrect Correct answer

Correction

Correct Incorrect Correct answer

Inspection

Correct Incorrect Correct answer

54. Question

A red warning light that activates when torque is below specification represents which type of Poka-Yoke?

Detection

Correct Incorrect Correct answer

Prevention

Correct Incorrect Correct answer

Correction

Correct Incorrect Correct answer

Randomization

Correct Incorrect Correct answer

55. Question

What is the goal of autonomous maintenance under Lean TPM?

Operators maintain their own equipment daily to detect and prevent issues early

Correct Incorrect Correct answer

Maintenance technicians handle all upkeep

Correct Incorrect Correct answer

Machines run until failure

Correct Incorrect Correct answer

Preventive maintenance is eliminated

Correct Incorrect Correct answer

56. Question

Total Productive Maintenance (TPM) primarily focuses on what objective?

Reducing employee headcount

Correct Incorrect Correct answer

Maximizing equipment uptime and effectiveness

Correct Incorrect Correct answer

Minimizing visual controls

Correct Incorrect Correct answer

Automating setup

Correct Incorrect Correct answer

57. Question

What three elements make up Overall Equipment Effectiveness (OEE)?

Quality, Safety, Productivity

Correct Incorrect Correct answer

Availability, Performance, Quality

Correct Incorrect Correct answer

Cost, Cycle Time, Reliability

Correct Incorrect Correct answer

Output, Input, Utilization

Correct Incorrect Correct answer

58. Question

Which statement best describes Kaizen?

A large-scale improvement project

Correct Incorrect Correct answer

A philosophy of continuous, incremental improvement involving everyone

Correct Incorrect Correct answer

A management-only initiative

Correct Incorrect Correct answer

A Six Sigma certification level

Correct Incorrect Correct answer

59. Question

How do Lean and Six Sigma complement each other?

Lean focuses on control charts; Six Sigma focuses on flow

Correct Incorrect Correct answer

Lean eliminates waste; Six Sigma reduces variation

Correct Incorrect Correct answer

Lean improves data collection; Six Sigma improves layout

Correct Incorrect Correct answer

They are unrelated

Correct Incorrect Correct answer

60. Question

What is the main purpose of Statistical Process Control (SPC)?

To eliminate all variation

Correct Incorrect Correct answer

To automate production

Correct Incorrect Correct answer

To monitor process stability and detect special-cause variation

Correct Incorrect Correct answer

To improve customer service

Correct Incorrect Correct answer

61. Question

Common-cause variation is best described as:

Natural variation inherent to the process

Correct Incorrect Correct answer

Variation from assignable events

Correct Incorrect Correct answer

Equipment breakdowns

Correct Incorrect Correct answer

Operator error

Correct Incorrect Correct answer

62. Question

Which example represents a special cause of variation?

Slight temperature differences

Correct Incorrect Correct answer

Random measurement noise

Correct Incorrect Correct answer

A failed machine sensor causing drift

Correct Incorrect Correct answer

Normal batch differences

Correct Incorrect Correct answer

63. Question

What is the primary purpose of a control chart?

To distinguish between common-cause and special-cause variation

Correct Incorrect Correct answer

To calculate Cp/Cpk

Correct Incorrect Correct answer

To predict customer complaints

Correct Incorrect Correct answer

To determine measurement bias

Correct Incorrect Correct answer

64. Question

How do control limits differ from specification limits?

Control limits are statistically calculated from process data; spec limits are customer requirements

Correct Incorrect Correct answer

They are identical

Correct Incorrect Correct answer

Both are set by management

Correct Incorrect Correct answer

Control limits never change

Correct Incorrect Correct answer

65. Question

SPC is most effective when a process is:

Completely stable

Correct Incorrect Correct answer

Stable and producing repetitive operations

Correct Incorrect Correct answer

In design phase

Correct Incorrect Correct answer

Under Six Sigma review

Correct Incorrect Correct answer

66. Question

An Xbar–R chart is typically used to monitor what type of data?

Subgrouped continuous data (e.g., diameter measurements)

Correct Incorrect Correct answer

Count data

Correct Incorrect Correct answer

Proportions

Correct Incorrect Correct answer

Attribute data

Correct Incorrect Correct answer

67. Question

When is an Individuals–Moving Range (I–MR) chart used?

For attribute data

Correct Incorrect Correct answer

When only one data point is collected per sample

Correct Incorrect Correct answer

When sample size ≥ 5

Correct Incorrect Correct answer

When using proportions

Correct Incorrect Correct answer

68. Question

Which control chart type is used for count or proportion data?

Xbar–R

Correct Incorrect Correct answer

P or NP charts

Correct Incorrect Correct answer

I–MR

Correct Incorrect Correct answer

X–S

Correct Incorrect Correct answer

69. Question

Why are “rational subgroups” important in control chart construction?

They ensure variation within a subgroup reflects only common causes

Correct Incorrect Correct answer

To make charts simpler

Correct Incorrect Correct answer

To increase chart limits

Correct Incorrect Correct answer

To lower cost

Correct Incorrect Correct answer

70. Question

Which control chart should be used to track the proportion of defective parts in samples of varying size?

P chart

Correct Incorrect Correct answer

NP chart

Correct Incorrect Correct answer

U chart

Correct Incorrect Correct answer

C chart

Correct Incorrect Correct answer

71. Question

When the sample size is constant and defects are counted as pass/fail items, which chart should be used?

NP chart

Correct Incorrect Correct answer

P chart

Correct Incorrect Correct answer

U chart

Correct Incorrect Correct answer

I–MR chart

Correct Incorrect Correct answer

72. Question

Which control chart monitors the number of defects per unit of inspection?

P chart

Correct Incorrect Correct answer

U chart

Correct Incorrect Correct answer

NP chart

Correct Incorrect Correct answer

C chart

Correct Incorrect Correct answer

73. Question

Which chart type is used for the total count of defects when the inspection area is constant?

C chart

Correct Incorrect Correct answer

U chart

Correct Incorrect Correct answer

P chart

Correct Incorrect Correct answer

Xbar–R chart

Correct Incorrect Correct answer

74. Question

What distinguishes variable data from attribute data in SPC?

Attribute data are continuous

Correct Incorrect Correct answer

Variable data are measured on a continuous scale; attribute data are counted or classified

Correct Incorrect Correct answer

Variable data are binary

Correct Incorrect Correct answer

Attribute data are random

Correct Incorrect Correct answer

75. Question

Increasing subgroup size on an Xbar–R chart generally results in what effect on control limits?

Narrower control limits due to reduced standard error

Correct Incorrect Correct answer

Wider control limits

Correct Incorrect Correct answer

No change

Correct Incorrect Correct answer

Unstable limits

Correct Incorrect Correct answer

76. Question

What does a single point beyond the upper control limit on a control chart indicate?

Common cause variation

Correct Incorrect Correct answer

Special cause variation — process likely unstable

Correct Incorrect Correct answer

Normal process drift

Correct Incorrect Correct answer

Operator bias

Correct Incorrect Correct answer

77. Question

According to Western Electric rules, what does “8 consecutive points on one side of the mean” indicate?

Common cause

Correct Incorrect Correct answer

Non-random pattern — likely special cause shift

Correct Incorrect Correct answer

Random fluctuation

Correct Incorrect Correct answer

Charting error

Correct Incorrect Correct answer

78. Question

In control chart rules, what does “2 of 3 points beyond 2σ” suggest?

A likely process mean shift

Correct Incorrect Correct answer

Random noise

Correct Incorrect Correct answer

Sampling error

Correct Incorrect Correct answer

Common-cause variation

Correct Incorrect Correct answer

79. Question

A control chart shows 7 points in a row trending upward. What does this pattern indicate?

Common cause

Correct Incorrect Correct answer

Special cause trend requiring investigation

Correct Incorrect Correct answer

Random pattern

Correct Incorrect Correct answer

Stability

Correct Incorrect Correct answer

80. Question

When is an Xbar–S chart used instead of an Xbar–R chart?

When subgroup sizes are greater than 10

Correct Incorrect Correct answer

When data are attribute-based

Correct Incorrect Correct answer

When only one point is available

Correct Incorrect Correct answer

When process mean is unknown

Correct Incorrect Correct answer

81. Question

What is the main difference between an I–MR and an Xbar–R chart?

Both use subgroups

Correct Incorrect Correct answer

I–MR uses individual data; Xbar–R uses subgroup averages

Correct Incorrect Correct answer

I–MR measures attribute data

Correct Incorrect Correct answer

Xbar–R uses moving averages

Correct Incorrect Correct answer

82. Question

Which control method can be used effectively when production volume is low or product mix is high?

Xbar–R chart

Correct Incorrect Correct answer

Short-run control charts (Z-charts or standardized charts)

Correct Incorrect Correct answer

P chart

Correct Incorrect Correct answer

U chart

Correct Incorrect Correct answer

83. Question

What is the primary advantage of an EWMA chart over an Xbar chart?

It is more sensitive to small, gradual process shifts

Correct Incorrect Correct answer

It ignores recent data

Correct Incorrect Correct answer

It tracks attribute defects

Correct Incorrect Correct answer

It requires large subgroups

Correct Incorrect Correct answer

84. Question

What is the purpose of a CUSUM (Cumulative Sum) chart?

To detect large, sudden changes

Correct Incorrect Correct answer

To detect small, persistent shifts in the process mean

Correct Incorrect Correct answer

To count defects

Correct Incorrect Correct answer

To estimate sigma level

Correct Incorrect Correct answer

85. Question

How do control charts differ from capability analysis?

Both measure process stability

Correct Incorrect Correct answer

SPC monitors ongoing stability; capability measures performance against specs

Correct Incorrect Correct answer

Capability uses time-series data

Correct Incorrect Correct answer

SPC measures customer tolerance

Correct Incorrect Correct answer

86. Question

A process is stable but has parts outside specification limits. What does this mean?

The process is in control but not capable

Correct Incorrect Correct answer

The process is unstable

Correct Incorrect Correct answer

The control limits are wrong

Correct Incorrect Correct answer

There are special causes

Correct Incorrect Correct answer

87. Question

A process shows good Cp/Cpk but frequent out-of-control points. What’s the correct interpretation?

Highly capable and stable

Correct Incorrect Correct answer

Capable but not in control — results are unpredictable

Correct Incorrect Correct answer

Stable but incapable

Correct Incorrect Correct answer

Statistically insignificant

Correct Incorrect Correct answer

88. Question

When a control chart shows a special cause signal, what is the correct first action?

Recalculate limits

Correct Incorrect Correct answer

Ignore one point

Correct Incorrect Correct answer

Investigate and eliminate the special cause

Correct Incorrect Correct answer

Shift the mean

Correct Incorrect Correct answer

89. Question

When should control limits be recalculated?

Every day

Correct Incorrect Correct answer

Whenever a point is out of control

Correct Incorrect Correct answer

After removing special causes and reestablishing process stability

Correct Incorrect Correct answer

Never

Correct Incorrect Correct answer

90. Question

Which of the following patterns signals a process shift according to Western Electric rules?

Eight or more consecutive points on one side of the center line

Correct Incorrect Correct answer

Random alternation around the mean

Correct Incorrect Correct answer

A single point near the center

Correct Incorrect Correct answer

Two points beyond 1σ

Correct Incorrect Correct answer

91. Question

A control chart shows points alternating high and low around the mean with no points near center. What pattern does this indicate?

Trend

Correct Incorrect Correct answer

Mixture — likely from combined sources or incorrect subgrouping

Correct Incorrect Correct answer

Shift

Correct Incorrect Correct answer

Cyclical variation

Correct Incorrect Correct answer

92. Question

What does a repeating up-down pattern in a control chart typically indicate?

Normal random variation

Correct Incorrect Correct answer

Cyclical variation due to periodic external influences (e.g., shifts, temperature)

Correct Incorrect Correct answer

Trend

Correct Incorrect Correct answer

Lack of variation

Correct Incorrect Correct answer

93. Question

When control chart points hug the center line tightly with very little variation, what does that suggest?

Stable process

Correct Incorrect Correct answer

Stratification — likely data from mixed sources or improper subgrouping

Correct Incorrect Correct answer

Normal behavior

Correct Incorrect Correct answer

Underlying trend

Correct Incorrect Correct answer

94. Question

Which run rule detects a trend in a control chart?

Two consecutive points outside 2σ

Correct Incorrect Correct answer

Seven points in a row steadily increasing or decreasing

Correct Incorrect Correct answer

Eight points on one side of mean

Correct Incorrect Correct answer

One point beyond 3σ

Correct Incorrect Correct answer

95. Question

A point beyond the upper control limit on an Xbar chart corresponds to which rule violation?

Rule 2

Correct Incorrect Correct answer

Rule 4

Correct Incorrect Correct answer

Rule 1: one point beyond 3σ

Correct Incorrect Correct answer

Rule 5

Correct Incorrect Correct answer

96. Question

What does “two of three consecutive points beyond 2σ on the same side of the mean” indicate?

Likely special cause variation

Correct Incorrect Correct answer

Random error

Correct Incorrect Correct answer

Stable process

Correct Incorrect Correct answer

Sampling bias

Correct Incorrect Correct answer

97. Question

“Fifteen consecutive points within 1σ of the center line” usually means:

Perfect control

Correct Incorrect Correct answer

Over-control or artificial uniformity

Correct Incorrect Correct answer

Stable process

Correct Incorrect Correct answer

Normal spread

Correct Incorrect Correct answer

98. Question

Why should data not be subgrouped by time of day if shift differences exist?

It increases sample size

Correct Incorrect Correct answer

It mixes distinct process conditions, masking true variation

Correct Incorrect Correct answer

It reduces outliers

Correct Incorrect Correct answer

It helps detect trends

Correct Incorrect Correct answer

99. Question

How can SPC be applied effectively in transactional or service environments?

By using only Xbar charts

Correct Incorrect Correct answer

By ignoring timing

Correct Incorrect Correct answer

By tracking key performance metrics like cycle time or error rate over time

Correct Incorrect Correct answer

By sampling one customer only

Correct Incorrect Correct answer

100. Question

What is the primary purpose of a control plan?

To record customer complaints

Correct Incorrect Correct answer

To document key process characteristics, controls, and response actions

Correct Incorrect Correct answer

To calculate Cp/Cpk

Correct Incorrect Correct answer

To standardize Lean 5S

Correct Incorrect Correct answer

101. Question

Who typically owns and maintains the process control plan?

The project sponsor

Correct Incorrect Correct answer

The process owner or area manager

Correct Incorrect Correct answer

The finance department

Correct Incorrect Correct answer

The Six Sigma Black Belt

Correct Incorrect Correct answer

102. Question

When should a control plan be updated?

Only during audits

Correct Incorrect Correct answer

Whenever process changes or new risks are identified

Correct Incorrect Correct answer

At year-end

Correct Incorrect Correct answer

Only after customer complaints

Correct Incorrect Correct answer

103. Question

What is the purpose of a reaction plan within the control plan?

To define the specific actions to take when a process goes out of control

Correct Incorrect Correct answer

To track financials

Correct Incorrect Correct answer

To recalculate control limits

Correct Incorrect Correct answer

To reassign responsibility

Correct Incorrect Correct answer

104. Question

Why is document control critical to sustaining process improvements?

It reduces staffing

Correct Incorrect Correct answer

It ensures only current, approved procedures are used

Correct Incorrect Correct answer

It lowers α risk

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It simplifies data entry

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105. Question

SOPs play what role in long-term process control?

They define consistent work methods and expectations for operators

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They serve as training checklists only

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They replace process owners

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They eliminate audits

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106. Question

What is the purpose of process audits in the Control phase?

To measure Cp

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To verify compliance with control plans and sustain gains

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To redesign experiments

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To check calibration

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107. Question

How do Poka-Yoke systems support process control?

By recording operator performance

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By preventing defects before they occur, reducing reliance on detection controls

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By tracking rework

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By verifying documentation

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108. Question

Which factor is most critical to sustaining process gains after project closure?

Management support and accountability

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Frequent data collection

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High sigma level

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External audits

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109. Question

Why is transferring project control to the process owner critical after DMAIC completion?

It embeds responsibility and ensures continued monitoring after the project ends

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To archive data

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To reassign belts

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To prepare new projects

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110. Question

Why is financial validation performed at the end of a Six Sigma project?

To update SOPs

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To confirm that documented savings are real, measurable, and sustained

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To calculate sigma level

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To assign process ownership

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111. Question

Which of the following best defines “hard savings”?

Direct, quantifiable cost reductions visible in the financial statements

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Estimated productivity gains

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Improved morale

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Inventory changes

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112. Question

What is an example of a “soft” saving?

Reduced raw material use

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Reduced cycle time improving customer satisfaction

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Lower scrap cost

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Reduced overtime

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113. Question

Why is ROI (Return on Investment) calculated in the Control phase?

To identify new projects

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To validate the financial return of implemented improvements

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To define process sigma

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To measure control chart accuracy

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114. Question

What is the main purpose of a control dashboard?

To list team members

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To display budget data

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To monitor key process metrics and ensure performance stays within limits

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To track Kaizen events

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115. Question

In a control dashboard, who should be accountable for each key metric?

The designated process owner

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The Green Belt

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The finance team

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The project sponsor

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116. Question

Which of the following is a standard deliverable at the end of the Control phase?

FMEA summary

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Updated control plan and SOPs with ownership assigned

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Design matrix

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Regression summary

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117. Question

What is the main objective of the project closure presentation?

To train new belts

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To conduct another DOE

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To communicate project results, financials, and control mechanisms to stakeholders

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To start the next phase

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118. Question

How often should control plan audits typically be conducted after implementation?

Periodically, based on process criticality (e.g., monthly or quarterly)

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Only annually

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Only during customer visits

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After three years

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119. Question

What is the ultimate objective of the Control phase?

To start a new DMAIC cycle

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To optimize inputs

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To sustain the gains and ensure performance remains within control

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To eliminate variation entirely

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