Lean Six Sigma Yellow Belt Training - Mock Exam.pdf

Lean Six Sigma Yellow Belt Training Mock Exam During a value stream analysis at Acme Corp., differences in cycle time between shifts have been identified. Which tool is best suited to visualise and analyse this issue? A) SIPOC B) Spaghett...

Lean Six Sigma Yellow Belt Training Mock Exam During a value stream analysis at Acme Corp., differences in cycle time between shifts have been identified. Which tool is best suited to visualise and analyse this issue? A) SIPOC B) Spaghetti Diagram C) Control Charts D) Pareto Chart ANSWER: C You are tasked with reducing material waste in the packing section and find that excessive movement and handling are damaging packaging materials. Which approach would most effectively address this issue? A) Implementing a Just-In-Time (JIT) system B) Redesigning job roles to increase worker accountability C) Applying 5S to improve organisation and efficiency D) Using error-proofing techniques to prevent handling errors ANSWER: C In an effort to decrease defects in part production, you suggest focusing on machine setup times and adjustments. Which methodology should be applied to facilitate rapid changeover times? A) Continuous improvement B) Quick setup methodology (SMED) C) Just-in-Time (JIT) D) Error prevention ANSWER: B Zeta Manufacturing is experiencing fluctuating product quality issues. Which tool would best help identify the root cause of defects? A) Pareto Chart B) Cause-and-effect diagram C) Check Sheets D) Flowcharts ANSWER: B Acme Corp wants to ensure the sustainability of process improvements. Which phase should be focused on to maintain and control standards? A) Analyse B) Control C) Improve D) Measure ANSWER: B While analysing a process, it's found that a step has an unusually high cycle time. What should be the next step after measuring and analysing this anomaly? A) Directly implement changes to reduce the step's cycle time B) Design experiments to test potential solutions for reducing cycle time C) Increase monitoring of the process step to gather more data D) Roll out changes based on industry best practices without further analysis ANSWER: B Upon reviewing the process flow, you find that several steps involve checking and re-checking for defects. Which principle can be applied to streamline the process while ensuring quality? A) Pull processing B) Total productive maintenance C) Just-in-time inventory D) Mistake-proofing (Poka Yoke) ANSWER: D During a project meeting, it was noted that inventory levels fluctuate significantly, affecting production. Which technique would help stabilise inventory levels? A) Levelling production B) Visual signalling system (Kanban) C) Workplace organisation (5S) D) Mapping the value stream ANSWER: B Acme Corp. is aiming to enhance its product delivery systems. Which tool is best suited to assess the current state of their delivery process from order to shipment? A) Process mapping analysis B) Gantt chart C) Critical path method D) Mapping the value stream ANSWER: D To address customer complaints about delayed deliveries, which approach would best improve delivery time? A) Increasing safety stock levels B) Expanding the delivery fleet C) Implementing a pull-based system to better match production with demand D) Conducting regular customer satisfaction surveys ANSWER: C In the control phase of a project, it is observed that the improvements are not sustained. What is the most likely cause of this issue? A) Insufficient training of the workforce B) Lack of proper documentation and standard operating procedures C) The improvements were not aligned with customer needs D) Overemphasis on automation and technology ANSWER: B If the goal is to reduce time wastage due to employees waiting for materials, which concept would directly address this issue? A) Just-In-Time delivery of materials B) Applying quick setup techniques for faster setup C) Analysing downtime for continuous process improvement D) Expanding warehouse space to increase material availability ANSWER: A A manufacturing process at Acme Corp. consistently produces a high rate of defective parts. Before making any changes, which tool should be used to ascertain the variability of the process? A) Pareto Analysis B) Failure Modes and Effects Analysis C) Control Charts D) Histogram ANSWER: C Which tool or technique would be best for a team looking to improve communication and reduce information delays in project management? A) Plan-Do-Check-Act cycle B) Communication plan using a responsibility assignment matrix C) Methodology for defining, measuring, analysing, improving, and controlling D) Critical Path Analysis ANSWER: B During a process optimisation project, multiple areas where non-value-added activities can be reduced are discovered. What is the first step you should take? A) Eliminate all identified non-value-added activities immediately B) Prioritise the non-value-added activities based on their impact on throughput C) Increase automation to reduce human-related non-value-added activities D) Conduct a cost-benefit analysis to determine which activities to eliminate first ANSWER: B A project team at Zeta Manufacturing needs to reduce process bottlenecks. What tool should they use to identify the sequence and flow of these bottlenecks within their operation? A) Process Flow Diagram B) Gantt Chart C) RACI Matrix D) Brainstorming Session ANSWER: A The company aims to minimise delays in its parts assembly line caused by machine malfunctions. Which preventive approach should be prioritised? A) Regular preventative maintenance checks B) Increased stock of replacement parts C) Training operators for quick on-site repairs D) Installing newer, more reliable machinery ANSWER: A During project evaluations, it's noted that task delegation could be clearer. Which tool would best clarify roles and responsibilities within the team? A) Fishbone Diagram B) SWOT Analysis C) RACI Chart D) Check Sheets ANSWER: C To enhance operational transparency, management decides to track real-time data of production processes. Which system is most effective for this purpose? A) ERP System B) Manual logging by workers C) Periodic audit reviews D) Customer feedback surveys ANSWER: A The company needs to assess the potential impact of new workflow changes on production capacity. Which analysis technique should they employ? A) Root cause analysis B) Simulation modelling C) Cost-benefit analysis D) Capacity requirement planning ANSWER: B Zeta Manufacturing wishes to reduce human error in its inventory recording. Which approach would be most direct and effective? A) Implementing bar code scanning B) Conducting regular inventory training sessions C) Manual double-checks by staff D) Outsourcing inventory management ANSWER: A A team wants to evaluate the customer satisfaction impact of a recent process change. Which method provides the most direct feedback? A) Focus groups with customers B) Internal review meetings C) Analysis of recent sales data D) Industry benchmarking ANSWER: A To optimise resource allocation, what technique should be used to ensure resources are directed to the most critical activities? A) Critical Path Method B) Eisenhower Box C) Pareto Analysis D) Heuristic Evaluation ANSWER: A To encourage innovation, the company wants to foster a culture where new ideas are evaluated systematically. Which technique should they integrate? A) Brainstorming sessions B) Idea ranking matrices C) Annual innovation workshops D) Suggestion box system ANSWER: B In response to fluctuating customer demand, which strategy should be implemented to adjust production levels quickly and efficiently? A) Economic order quantity B) Demand forecasting C) Agile methodology D) Cross-training employees ANSWER: C To decrease material wastage due to transportation damage, which quality control tool should be utilised to track and analyse when and where the damage occurs? A) Ishikawa Diagram B) Scatter Plot C) Control Chart D) Run Chart ANSWER: B When considering changes to the supplier selection process to improve material quality, what evaluation technique should be used to decide between potential suppliers? A) Supplier scorecard B) Total cost of ownership analysis C) SWOT analysis of suppliers D) Return on investment calculations ANSWER: A To improve team communication and project tracking, which tool should be introduced for daily updates and progress tracking? A) Kanban board B) Daily stand-up meetings C) Email updates D) Weekly newsletter ANSWER: A Management wants to understand why a specific product line is not achieving the planned profit margins. Which approach should they use to identify the cost drivers? A) Activity-based costing B) Standard costing C) Direct labour cost analysis D) Variable costing technique ANSWER: A To increase the success rate of new projects, what technique should be used to forecast potential risks and their impacts before project launch? A) Risk matrix B) Probability and impact grid C) Fault tree analysis D) Delphi method ANSWER: B